Motor manufacturing method

ABSTRACT

A plurality of single-pole coils are retained by a coil retaining device, the single-pole coils are arranged such that the coil insertion portions of each single-pole coil confront the inner circumference openings of the slots and may be generally parallel to the axial direction of the motor core, each single-pole coil is moved linearly toward the motor core such that the coil retaining device and the moving locus before the adjoining coil insertion portions in the adjoining single-pole coils are inserted into the slots are parallel or approach the more from the inner circumference side to the outer circumference side and the two coil insertion portions of each single-pole coil are moved such that they may start their movements simultaneously and at equal velocities.

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention relates to a process for manufacturing a motor and, moreparticularly, to a process for inserting a coil into a motor core.

2. Description of Related Art

The motor manufacturing process of a motor with a stator prepared byinserting a coil into slots of a motor core, such as a stator core orrotor core, is important. A variety of coil inserting processes orapparatus have been proposed.

In the coil inserting process of JP-A-2000-125522; JP-A-2000-116078; andJP-A-9-322492, for example, the so-called “inserter method” is used. Abrief description of one example of the inserter method will bedescribed with reference to FIGS. 66-68. As shown in FIG. 66 and FIG.67, a ring-shaped stator core 1 is arranged in a horizontal posture, anda coil 8 is also arranged generally in the horizontal posture axiallybelow the stator core 1. A jig (not shown) is lifted from below the coil8 through the inside of the stator core 1, and the inner side end 81 ofthe coil 8 is hooked and moved upward by the jig. As a result, the coil8 is moved to rub the inner circumference of the stator core 1 whilechanging its state gradually from the horizontal posture to the verticalposture. As such, the coil 8 is inserted into the slots 10 of the statorcore 1.

SUMMARY OF THE INVENTION

However, the following problems are included in the motor manufacturingprocess using the above described inserter method. In the insertermethod, the coil 8 is inserted, while changing its state, into the slots10 of the stator core 1 as described hereinbefore. While the state ofthe coil changes, there arises a state in which the coil 8 is insertedin an oblique posture. As shown in FIG. 68, therefore, the size of thecoil 8 has to be given a surplus at least in its vertical length L0. Asa result, at the time when insertion has been completed, the coil 8takes a state in which the coil end portion at its upper end portion orits lower end portion bulges more than necessary from the stator core 1.

This bulge of the coil end portion of the coil 8 leads to an enlargementin the axial size of the entire motor that has the coil assembled in thestator core as described hereinbefore. This problem, as described above,also occurs when the motor core has the coil inserted not only in thestator core but also in the rotor core.

There is thus a need to adopt an electric motor or a hybrid system in anautomobile, wherein the axial size of the motor is reduced.

The invention thus provides a motor manufacturing process that can,among other things, reduce the bulge extents of the coil from the motorcore and reduce the axial length of the motor.

According to a first exemplary aspect of the invention, a method formanufacturing a motor with a ring-shaped motor core having slots formedin an inner circumference of the motor core and in which coils areinserted and arranged in the slots, comprising forming a plurality ofsingle-pole coils that include two coil insertion portions and two coilend portions that connect the coil insertion portions; and inserting thecoil insertion portions into the slots, by retaining the single-polecoils at or after the forming of the coils; arranging the single-polecoils such that the coil insertion portions of each of the single-polecoils confront inner circumference openings of the slots and aregenerally parallel to an axial direction of the motor core; moving eachof the single-pole coils substantially linearly toward the motor coresuch that each of the single-pole coils move from a retained positionand a moving direction of adjoining coil insertion portions, before theadjoining coil insertion portions of adjoining single-pole coils areinserted into the slots, are substantially parallel or approach eachother from an inner circumference side to an outer circumference side;and moving the two coil insertion portions of each single-pole coil suchthat the coil insertion portions start moving simultaneously and atequal velocities.

According to a second exemplary aspect of the invention, the inventionincludes a method for manufacturing a motor with a ring-shaped motorcore having slots formed in an inner circumference of the motor core andin which coils are inserted and arranged in the slots, comprisingforming a plurality of single-pole coils that include two coil insertionportions and two coil end portions that connect the coil insertionportions; and inserting the coil insertion portions into the slots byretaining the single-pole coils at or after the forming of the coils;arranging the single-pole coils such that the coil insertion portions ofeach of the single-pole coils confront inner circumference openings ofthe slots and are generally parallel to an axial direction of the motorcore; moving the each of the single-pole coils substantially linearlytoward the motor core such that each of the single-pole coils move froma retained position and a moving direction of adjoining coil insertionportions, before the adjoining coil insertion portions of adjoiningsingle-pole coils are inserted into the slots, are substantiallyparallel or approach each other from an inner circumference side to anouter circumference side; and moving the two coil insertion portions ofeach single-pole coil, such that the coil insertion portions aresimultaneously inserted into the slots.

According to a third exemplary aspect of the invention, the inventionincludes a method for manufacturing a motor with a ring-shaped motorcore having slots formed in an inner circumference of the motor core andin which coils are inserted and arranged in the slots, comprisingforming a plurality of single-pole coils having two coil insertionportions and two coil end portions that connect the coil insertionportions; placing the coils in a magazine, wherein the magazine has ashape such that the magazine can be arranged on an inner side of theinner circumference of the motor core, is provided in an outercircumference of the magazine with a plurality of coil retaining groovesat positions confronting the slots of the motor core as to arrange thecoil insertion portions of the single-pole coil, and the coil retaininggrooves for arranging the adjoining coil insertion portions in theadjoining single-pole coils are arranged either in parallel with eachother or to approach each other from the inner circumference side to theouter circumference side, wherein the coil insertion portions of thesingle-pole coils are inserted into the coil retaining grooves to retainthe coils on the magazine; arranging the magazine inside the motor coreso that the coil retaining grooves of the magazine confront the slots ofthe motor core; and inserting the coil insertion portions of thesingle-pole coils into the slots, by bringing a coil inserting deviceinto abutment against all the single-pole coils on the magazine toadvance abutting portions in a direction from a center of the magazineto the outer circumference, thereby to move each of the single-polecoils substantially linearly toward the motor core such that the coilsleave the magazine and such that the two coil insertion portions of eachsingle-pole coil may start moving simultaneously and may take equalvelocities.

According to a fourth exemplary aspect of the invention, the inventionincludes a method for manufacturing a motor with a ring-shaped motorcore having slots formed in an inner circumference of the motor core andin which coils are inserted and arranged in the slots, comprisingforming a plurality of single-pole coils that include two coil insertionportions and two coil end portions that connect the coil insertionportions; placing the coils in a magazine, wherein the magazine has ashape such that the magazine can be arranged on an inner side of theinner circumference of the motor core, an outer circumference of themagazine is provided with a plurality of coil retaining grooves atpositions confronting the slots of the motor core as to arrange the coilinsertion portions of the single-pole coil, and in which said coilretaining grooves for arranging adjoining coil insertion portions in theadjoining single-pole coils are arranged either in parallel with eachother or to approach each other from an inner circumference side to anouter circumference side, wherein the coil insertion portions of thesingle-pole are inserted into the coil retaining grooves to retain thecoils on the magazine; arranging the magazine inside of the motor coresuch that the coil retaining grooves of the magazine confront the slotsof the motor core; and inserting the coil insertion portions of thesingle-pole coils into the slots, by bringing a coil inserting deviceinto abutment against all the single-pole coils on the magazine toadvance abutting portions in a direction from a center of the magazineto the outer circumference, thereby to move each of the single-polecoils substantially linearly toward the motor core such that the coilsleave the magazine and such that the two coil insertion portions of eachsingle-pole coil may be simultaneously inserted into the slots.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention will be described with reference tothe drawings wherein:

FIG. 1 is an explanatory view showing the state in which coils are woundon winding frames by a winding arm;

FIG. 2 is an explanatory view showing the state in which the formationsof three coils are completed;

FIG. 3 is an explanatory view showing the state in which the shapes ofthe three coils are being profiled;

FIG. 4 is an explanatory view showing the state just before a transferdevice is inserted into the coil on the winding frame;

FIG. 5 is an explanatory view showing the state just after transferdevice is inserted into the coil on the winding frame;

FIG. 6 is an explanatory view showing the state in which the transferdevice is inserted into the coil on the winding frame and clamps thecoil;

FIG. 7 is an explanatory view showing the state in which the coil on thewinding frame is pulled out by the transfer device;

FIG. 8 is an explanatory view showing the state of in which the coil istransferred from the transfer device to a magazine;

FIG. 9 is an explanatory view showing the state in which the magazine isarranged in a stator core and in which insertion blades and provisionalshaping blades are inserted into grooves;

FIG. 10 is an explanatory view showing the state in which the insertionblades and the provisional shaping blades are moved;

FIG. 11 is an explanatory view showing the state in which the insertionblades and the provisional shaping blades are completely moved;

FIG. 12 is an explanatory view showing the state in which upper andlower formers are being advanced toward the stator core;

FIG. 13 is an explanatory view showing the state in which the locus ofthe coil when the coil is inserted into the stator core is perspectivelytaken;

FIG. 14 is an explanatory view showing the state in which the locus ofthe coil when the coil is inserted into the stator core is taken fromthe side;

FIG. 15 is an explanatory view of showing the size of the coil insertedinto the stator core;

FIG. 16 is an explanatory view showing the arrangement relation ofsingle-pole coils of individual phases to be inserted into the statorcore;

FIG. 17 is an explanatory view showing the overlapping state of a coilend portion of the single-pole coils of individual phases to be insertedinto the stator core;

FIG. 18 is an explanatory view showing a construction of a coilinserting apparatus;

FIG. 19 is an explanatory view showing the motions of insertion bladesand so on of the coil inserting apparatus;

FIGS. 20A and 20B are explanatory views showing the shape and motion ofthe insertion blades;

FIGS. 21A-29C are explanatory views showing the shape and motion of theinsertion blades from the side;

FIGS. 22A-22C are explanatory views showing the shape and motion of theinsertion blades from above;

FIG. 23 is an explanatory view showing the structure of a magazine fromthe front;

FIG. 24 is an explanatory view showing the structure of the magazinefrom the side;

FIG. 25 is an explanatory view showing the structure of the magazinefrom the upper face;

FIG. 26 is an explanatory view showing the structure of a magazine fromthe front;

FIG. 27 is an explanatory view showing the structure of the magazinefrom the side;

FIG. 28 is an explanatory view showing the structure of the magazinefrom the upper face;

FIG. 29 is an explanatory view showing an example of the appliedpositions of an insertion pressure to be applied to the single-polecoil;

FIG. 30 is an explanatory view showing an example of the appliedpositions of the insertion pressure to be applied to the single-polecoil;

FIG. 31 is an explanatory view showing an example of the appliedpositions of the insertion pressure to be applied to the single-polecoil;

FIG. 32 is an explanatory view showing an example of the appliedpositions of the insertion pressure to be applied to the single-polecoil;

FIG. 33 is an explanatory view showing an example of the appliedpositions of the insertion pressure to be applied to the single-polecoil;

FIG. 34 is an explanatory view showing an example of the appliedpositions of the insertion pressure to be applied to the single-polecoil;

FIG. 35 is an explanatory view showing a structure of split insertionhooks;

FIG. 36 is an explanatory view showing another example of the structureof the split insertion hooks;

FIG. 37 is an explanatory view showing a construction of a coil formingapparatus;

FIG. 38 is an explanatory view showing the state in which a coil isformed by the coil forming apparatus;

FIG. 39 is an expanded explanatory view showing a structure of a take-upjig;

FIG. 40 is an explanatory view showing the state in which all thewinding frames of the take-up jig are retracted;

FIG. 41 is an explanatory view showing the state in which the firstwinding frame of the take-up jig is advanced;

FIG. 42 is an explanatory view showing the state in which the take-upjig is turned on the axis of the first winding frame to wind theelectric line;

FIG. 43 is an explanatory view showing the state in which the electricline is completely wound on the first winding frame;

FIG. 44 is an explanatory view showing the state in which the firstwinding frame is retracted;

FIG. 45 is an explanatory view showing the state in which the secondwinding frame of the take-up jig is advanced;

FIG. 46 is an explanatory view showing the state in which the take-upjig is turned on the axis of the second winding frame to wind theelectric line completely;

FIG. 47 is an explanatory view showing the state in which the secondwinding frame is retracted;

FIG. 48 is an explanatory view showing the state in which a thirdwinding frame of the take-up jig is advanced;

FIG. 49 is an explanatory view showing the state in which the take-upjig is turned on the axis of the third winding frame to wind theelectric line completely;

FIG. 50 is an explanatory view showing the state in which the thirdwinding frame is retracted;

FIG. 51 is an explanatory view showing a structure for fixing thewinding frame at the retracted position;

FIG. 52 is an explanatory view showing the state in which thepositioning pins of the winding frame are disengaged from a guide plate;

FIG. 53 is an explanatory view showing a structure for fixing thewinding frame at the advanced position;

FIG. 54 is an explanatory view showing the state in which the take-upjig is arranged in the stator core;

FIG. 55 is an explanatory view showing the state in which the insertionblades and the provisional shaping blades inserted into the take-up jigare advanced;

FIG. 56 is a perspective view showing a wedge;

FIG. 57 is an explanatory view showing the state in which the wedge ismounted in the slot of the stator core;

FIG. 58 is an explanatory view showing a structure of an insertionapparatus;

FIG. 59 is a section taken along line I-I of FIG. 58;

FIG. 60 is a section taken along line II-II of FIG. 58;

FIG. 61 is an explanatory view showing the state in which the working ofa wedge pusher of the insertion apparatus is started;

FIG. 62 is an explanatory view showing the state in which the wedgepusher of the insertion apparatus abuts against a blade unit;

FIG. 63 is an explanatory view showing the state in which the wedge ispushed from the insertion apparatus into the slot of the stator core;

FIG. 64(a) is an explanatory view showing the state of coil insertingmeans taken in the axial direction of the stator core and before apusher plate is advanced;

FIG. 64(b) is an explanatory view showing the state of the coilinserting means taken in the axial direction of the stator core andafter the pusher plate is completely advanced;

FIG. 65(a) is an explanatory view showing the state of the coilinserting means taken along line III-III of FIG. 64 and before thepusher plate is advanced;

FIG. 65(b) is an explanatory view showing the state of the coilinserting means taken along line III-III of FIG. 64 and after the pusherplate is completely advanced;

FIG. 66 is an explanatory view showing the state of a related artexample, in which the locus of the coil when the coil is inserted intothe stator core is perspectively taken;

FIG. 67 is an explanatory view showing the state of the prior relatedexample, in which the locus of the coil when the coil is inserted intothe stator core is taken from the side; and

FIG. 68 is an explanatory view of the related art example showing thesize of the coil inserted into the stator core.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A motor manufacturing process according to a first embodiment of theinvention will be described with reference to FIGS. 1-15. A motor to bemanufactured by the process of this embodiment includes: a ring-shapedmotor core (or stator core) 1 (FIG. 9 to FIG. 12) having a plurality ofslots 10 formed in its inner circumference; and a coil group of threephases (U-phase, V-phase and W-phase) (FIG. 16 and FIG. 17). In thismotor manufacturing process, the coil group of each phase is composed ofa plurality of single-pole coils 8 constructing one pole. Eachsingle-pole coil 8 is inserted into and arranged in the stator core 1across two slots 10. The single-pole coils 8 belonging to the coilgroups of the different phases have their coil end portions 802partially overlapping each other when they are mounted in the statorcore 1.

The manufacturing process of this embodiment includes a coil formingstep and a coil inserting step.

As shown in FIG. 1 to FIG. 3, the coil forming step forms the coil,which includes: the single-pole coil 8 having two coil insertionportions 801 inserted into the slots 10; and the two coil end portions802 so arranged outside of the stator core 1 as to join the coilinsertion portions 801.

At the coil inserting step, on the other hand, the single-pole coils 8are individually arranged generally in parallel with the innercircumference openings of the slots 10 by the coil insertion portions801 with the coil insertion portions 801 individually kept at an angleof inclination within 5 degrees with respect to the axial direction ofthe stator core 1, as shown in FIG. 9 to FIG. 11. With this arrangement,the single-pole coils 8 are simultaneously moved generally linearlytoward the stator core 1 so that the coil insertion portions 801 of thesingle-pole coils 8 are simultaneously inserted into the slots 10. Atthis time, moreover, the adjoining single-pole coils 8 are moved suchthat the moving loci (e.g., a2 and b1, and b2 and c1 in FIG. 8) beforetheir adjoining coil insertion portions 801 are inserted into the slots10 may be in parallel with each other. Moreover, the two coil insertionportions 801 of each single-pole coil 8 start their movementssimultaneously and take equal velocities.

At the coil inserting step of this embodiment, there is used a magazine2, which has such a disc shape as can be arranged on the inner side ofthe inner circumference of the stator core 1 and which is provided inits outer circumference with a plurality of coil retaining grooves 20for arranging the coil insertion portions 801 of the single-pole coils 8at positions confronting the slots 10 of the stator core 1, as shown inFIG. 8. Of the coil retaining grooves 20, those (e.g., 20A2 and 20B1,and 20B2 and 20C1 in FIG. 8) for arranging the adjoining coil insertionportions 801 of the adjoining single-pole coils 8 are arranged inparallel with each other. The coils 8 (or the coil insertion portions801) are inserted into and arranged in the coil retaining grooves 20,and the magazine 2 is arranged in the stator core 1 so that the coilretaining grooves 20 of the magazine 2 confront the slots 10 of themotor core 1.

Next, as shown in FIG. 9, insertion blades 3, as an example of a coilinserting means, are caused to abut against the coils 8 and are advancedfrom the center to the outer circumference of the magazine 2. Theinsertion blades 3 thus move the coils 8 from the coil retaining grooves20 into the slots 10 of the stator core 1.

The more detailed description will be made in the following. The motorto be manufactured in the invention is a three-phase DC brushless motor.The stator core 1 of this embodiment is prepared by laminatingring-shaped electromagnetic steel sheets, and an inner circumference ofthe motor core 1 is provided with seventy two slots 10 in total, asshown in FIG. 9 to FIG. 12 and FIG. 16.

Here will be briefly described an example of the arrangement of thecoils 8 in the individual slots 10 of the stator core 1. In thisembodiment, for the stator core 1, thirty six single-pole coils 8 intotal are divided into three groups of twelve single-pole coils 8 intotal, as corresponding to one phase.

The individual slots 10 are serially numbered from first to seventysecond. For the first group, one single-pole coil is inserted to formturns through the first slot and the sixth slot. Next to this, anothersingle-pole coil is inserted to form turns through the seventh slot andthe twelfth slot. Next to this, one single-pole coil is arranged forevery six slots. As shown in FIG. 16, therefore, twelve single-polecoils 8 of the coil group belonging to the U-phase are first insertedinto the inner circumference of the stator core 1 and are arranged inthe adjoining state.

The single-pole coils 8 belonging to the second and third groups (i.e.,the V-phase and W-phase) are arranged with shifts of two and four slots,respectively, in the circumferential direction from the arranged stateof the first group. As shown in FIG. 16, therefore, all the single-polecoils 8 are mounted in the stator core 1 such that the coil end portions802 of the single-pole coils 8 belonging to the U-phase are partiallyoverlapped from the inner circumference side of the stator core 1 by thecoil end portions 802 of the single-pole coils 8 belonging to theV-phase. Also, the coil end portions 802 of the single-pole coils 8belonging to the V-phase are partially overlapped from the innercircumference side of the stator core 1 by the coil end portions 802 ofthe single-pole coils 8 belonging to the W-phase. As shown in FIG. 17,the coil end portions 802 of the individual phases are finally packed socompactly at a provisional shaping step and a proper shaping step to bedescribed hereinafter that they are deformed outward from the slots 10.

In this embodiment, moreover, the magazine 2 is used to handle one group(of one phase), i.e., the twelve single-pole coils 8 at once so that thethirty six single-pole coils 8 in total are mounted in the stator core 1by the works of three times.

As shown in FIG. 8, the magazine 2 includes: the paired left and rightcoil retaining grooves 20; a pair of shallowed left and rightpreparatory grooves 22 positioned between the coil retaining grooves 20;and a pair of left and right provisional shaping grooves 24 positionedbetween the preparatory grooves 22. If these six grooves are bundledinto one group, moreover, twelve groups are disposed adjacent to eachother over the outer circumference of the magazine 2. Moreover, all theadjoining grooves are disposed to confront the slots 10 in the statorcore 1 (although partially omitted from FIG. 8 to FIG. 12).

Moreover, all the individual preparatory grooves 22 are arranged alongthe radial directions and are oriented in radially different directions.On the other hand, the coil retaining grooves 20 are so arranged inparallel as to make one pair with the coil retaining grooves 20 arrangedadjacent to each other for receiving the adjoining single-pole coils 8.Moreover, the paired provisional shaping grooves 24 are arranged inparallel to each other.

Before using the magazine 2 thus constructed, a winder step is performedfor forming the coils. At this winder step, the single-pole coils 8 areformed three by three.

For this winder step, as shown in FIG. 1, there are used threejuxtaposed winding frames 5 and a winding arm 59 for feeding a wire (oran electric line) 88 and winding it on the winding frames 5.

As shown in FIG. 1, each winding frame 5 is provided with four upper,lower, left and right pawl portions 51, and in its left and right sidefaces with cutouts 52 for allowing a later-described transfer device 6to easily insert thereinto. Moreover, the pawl portions 51 areopened/closed leftward and rightward so that they are opened leftwardand rightward to have a larger diameter when they wind the wire.Moreover, each winding frame 5 can be moved forward and backward as awhole and can turn leftward and rightward.

The winding arm 59 is constructed to feed the wire 88 while turningaround the winding frames 5 in the advanced states. The turningdirection is, moreover, constructed to be changeable.

At first, the winding frame 5 at the left end is advanced (although notshown), and the wire 88 is fed while the winding arm 59 is turnedclockwise around the winding frame 5 at the left end. As a result, thefirst single-pole coil 8 is formed.

Next, the left side winding frame 5 is retracted, and the centralwinding frame 5 is advanced (although not shown). Then, the wire 88 isfed while the winding arm 59 is turned counter-clockwise around thecentral winding frame 5. As a result, the second single-pole coil 8 isformed.

Moreover, as shown in FIG. 1, the central winding frame 5 is retracted,and the right end winding frame 5 is advanced. Then, the wire 88 is fedwhile the winding arm 59 being turned again clockwise (in the directionof arrow A) around the right end winding frame 5. As a result, the thirdsingle-pole coil 8 is formed.

Next, the right end winding frame 5 is retracted so that the threewinding frames 5 are arranged in a line, as shown in FIG. 2. Next, theleft and right winding frames 5 are slightly turned outside, as shown inFIG. 3, so that the three single-pole coils 8 are tensed to adjust theirshapes.

Next, in this embodiment, the three single-pole coils 8 thus formedaround the three winding frames 5 are transferred from the windingframes 5 to the magazine 2 by the transfer device 6, as shown in FIG. 4to FIG. 8.

As shown in FIG. 4 to FIG. 7, the transfer device 6 is provided with twobase plates 61 and clamp plates 62 individually arranged outside of thebase plates 61. These base plates 61 and clamp plates 62 can be turnedor opened/closed in the horizontal directions.

When this transfer device 6 is used to perform the coil transferringactions actually, the pawl portions 51 of the winding frame 5 are closedat first to the left and right to reduce the external diameter of thewinding frame 5, as shown in FIG. 4. As a result, a clearance isestablished between the winding frame 5 and the single-pole coil 8formed around the winding frame 5.

Moreover, the transfer device 6 is positioned in parallel to adjust theclearance of the base plates 61 to the position of the clearance betweenthe winding frame 5 and the single-pole coil 8. Moreover, the clampplates 62 are opened to the left and right from the base plates 61.

Next, the base plates 61 of the transfer device 6 are inserted into theclearances between the winding frame 5 and the single-pole coil 8, asshown in FIG. 5. As shown in FIG. 6, the clamp plates 62 are then closedto clamp the single-pole coil 8 between the clamp plates 62 and the baseplates 61. As shown in FIG. 7, the transfer device 6 is retracted tocomplete the removal of the single-pole coil 8 from the winding frame 5.

Next, the transfer device 6 is so arranged that it confronts the outercircumference of the magazine 2, and that the outer side faces 610 ofits base plates 61 are generally in parallel with the inner side facesof the coil retaining grooves 20, as shown in FIG. 8. And, the clampplates 62 are slightly opened to make the single-pole coil 8 movable,and this single-pole coil 8 is pushed and transferred by the not-shownpusher into the coil retaining grooves 20 of the magazine 2. At thistime, the single-pole coil 8 is not pushed deeply into the coilretaining grooves 20 but leaves such clearances between itself and thebottom portions 29 of the coil retaining grooves 20 so that thelater-described insertion blades 3 may be inserted thereinto.

By performing these actions at once with the three transfer devices 6,the three single-pole coils 8 formed around the three winding frames 5can be transferred at once to the magazine 2. Here, in case theindividual single-pole coils 8 may be separated, one transfer device 6can also be used to transfer the single-pole coils 8 one by one.

By repeating the forming and transferring works of the three coils withthe winding frames 5 thus far described four times, moreover, the twelvesingle-pole coils 8 are arranged on the outer circumference of themagazine 2.

Here, the formation to the transfer of the coils to the magazine 2 canalso be rationalized by increasing the facilities of the winding frames5, the winding arms 59 and the transfer devices 6 to proceed inparallel.

Next, the coils are moved from the magazine 2 to the stator core 1. Atfirst, the magazine 2 is so arranged in the stator core 1 that the coilretaining grooves 20 of the magazine 2 confront the slots 10 of thestator core 1, as shown in FIG. 9.

At this time, all the single-pole coils 8 on the magazine 2 are soarranged that their coil insertion portions 801 are generally inparallel with the corresponding slots 10. And, the angle made betweenthe coil insertion portions 801 and the axial direction of the statorcore 1 is kept within 5 degrees at this time.

Moreover, the insertion blades 3 are inserted into the clearances in thecoil retaining grooves 20 of the magazine 2. On the other hand,provisional shaping blades 34 are inserted into the provisional shapinggrooves 24 of the magazine 2.

As shown in FIG. 10 and FIG. 11, moreover, the insertion blades 3 areadvanced in the coil retaining grooves 20 in the directions from thecenter to the outer circumference, and the provisional shaping blades 34are advanced in the provisional shaping grooves 24 in the directionsfrom the center to the outer circumference. As a result, the single-polecoils 8 are pushed by the insertion blades 3 so that they move from thecoil retaining grooves 20 to the slots 10 of the stator core 1.

Moreover, the upper and lower coil end portions 802, as bulging out ofthe stator core 1, of the single-pole coils 8 are pushed and deformedoutward by the provisional shaping blades 34 so that they are subjectedto the provisional shaping treatment.

These advancing actions of the insertion blades 3 and the provisionalshaping blades 34 are simultaneously performed for all the twelvesingle-pole coils 8 so that these twelve single-pole coils 8 of onegroup are simultaneously inserted into the slots 10 of the stator core1.

At this time, the angle made between the individual coil insertionportions 801 and the stator core 1 is kept within 5 degrees even duringthe movements. Therefore, all the single-pole coils 8 are simultaneouslymoved generally linearly toward the stator core 1 so that the coilinsertion portions 801 of all the single-pole coils 8 are simultaneouslyinserted into the slots 10.

Of the coil retaining grooves 20 (e.g., 20A1-20C2) of the magazine 2thus far described, moreover, there are arranged in parallel the coilretaining grooves (e.g., 20A2 and 20B1, and 20B2 and 20C1 in FIG. 8) forarranging the adjoining coil insertion portions 801 in the adjoiningsingle-pole coils 8. Therefore, the coil insertion portions 801 of eachsingle-pole coil 8 move such that their moving loci (e.g., a2 and b1,and b2 and c1 in FIG. 8) before they are inserted into the slots 10 areparallel.

Moreover, the insertion blades 3 for pushing the coil insertion portionsare completely synchronized from the start to the stop of their movementso that the two coil insertion portions 801 owned by each single-polecoil 8 start their movements simultaneously and move at the equalvelocities.

Next, in this embodiment a second provisional shaping step is performedby using a pair of upper and lower formers 66, which are also used inthe proper shaping step.

As shown in FIG. 12, the formers 66 have ring shapes, as shown in FIG.12, and are provided, on their sides confronting the stator core 1, withshaping faces 660 for profiling the coils into a desired shape.Specifically, the upper and lower individual formers 66 have the taperedshaping faces 660, the inner circumference portions of which protrudetoward the stator core 1. And, the formers 66 are constructed such thatthe coils 8 are shaped outward along the tapered shapes of the shapingfaces 660 by advancing the formers 66 to the stator core 1.

Moreover, each former 66 is provided with cutouts 665 for preventing theinsertion blades 3 and the provisional shaping blades 34 frominterfering each other. And, the formers 66 can be pushed onto thestator core 1 while the insertion blades 3 and the provisional shapingblades 34 are advanced.

The paired upper and lower formers 66 thus constructed are individuallyadvanced from their upper and lower positions and pushed onto the statorcore 1. As a result, the second provisional shaping is performed suchthat the coil end portions 802, as bulging out from above and below thestator core 1, of the twelve single-pole coils 8 thus arranged in thestator core 1 fall down toward the stator core 1.

Next, the coil forming works using the winding frames 5 and the windingarm 59 and the coil transferring works using the transfer device 6 areperformed to insert and arrange the twelve single-pole coils 8 of thesecond group in the magazine 2.

Like before, moreover, the magazine 2 is so arranged inside of thestator core 1 that the coil retaining grooves 20 of the magazine 2confront the slots 10 of the stator core 1. At this time, the magazine 2and the stator core 1 are arranged at such circumferentially shiftedpositions that the coils of the first phase of the first group and thecoils of the second group are shifted. Next, there are performed themovements of the coils 8 using the insertion blades 3 and theprovisional shaping using the provisional shaping blades 34. Stillmoreover, the second provisional shaping is performed by using thepaired upper and lower formers 66 like the above.

Next, the twelve single-pole coils 8 of the third group are worked as inthe cases of the first and second groups. At the moving time of thecoils from the magazine 2 to the stator core 1, however, the relativepositions of the magazine 2 and the stator core 1 are socircumferentially shifted that the third group (or the third phase) maybe shifted with respect to the first group (or the first phase) and thesecond group (or the second phase).

On the other hand, the second provisional shaping of the third group isresultantly the proper shaping step. In other words, at the stage wherethe coils of the third group are inserted into the stator core 1, all ofthe thirty six single-pole coils 8 are mounted in the stator core 1.Moreover, the provisional shaping by the provisional shaping blades 34is directly performed exclusively on the twelve single-pole coils 8 ofthe third group. On the other hand, the shaping to be performed as thesecond provisional shaping by the formers 66 is performed on all thethirty six single-pole coils 8 so that it becomes the proper shapingstep for profiling the entire coil shape. Thus, the thirty sixsingle-pole coils 8 in total are inserted and arranged in the statorcore 1, and the proper shaping is in the completed state.

Here in this embodiment, a series of works are performed from theformation of the twelve single-pole coils of the individual groups tothe second provisional shaping. By using three sets of magazines 2,however, the works could naturally be done in parallel with three setsfrom the coil shaping to the insertion and arrangement of the coils inthe magazine 2 so that they might be rationalized.

By making use of the magazine 2 and the insertion blades 3, as describedhereinbefore, this embodiment can execute the so-called “linearinsertion method” easily and stably. As shown in FIG. 13 and FIG. 14,more specifically, the coils 8 can be linearly inserted without changingtheir postures into the slots 10. Therefore, it is not necessary toenlarge the vertical length of the coils 8 more than necessary. As shownin FIG. 15, more specifically, the vertical size L1 of the coils 8inserted into the stator core 1 can be made sufficiently shorter thanthe vertical size L0 of the prior art, as shown in FIG. 68.

Therefore, it is possible to prevent the coils 8 from excessivelybulging out of the stator core 1 and to reduce the axial length of theparts constructed by mounting the coils 8 in the stator core 1 andaccordingly the axial length of the entire motor.

In this embodiment, moreover, the moving loci of the adjoining coilinsertion portions 801 of the adjoining single-pole coils 8 areparallel, as described hereinbefore. Even when the stator core 1 has asmall diameter or uses many turns (or windings) of single-pole coils 8,these single-pole coils 8 can be easily arranged on the innercircumference side of the stator core 1, thereby to add an effect thatthe coil inserting step can be easily performed.

Noting the movements of the individual single-pole coils 8 one by one,moreover, the two coil insertion portions 801 owned by each single-polecoil 8 start their movements simultaneously and move at the equalvelocities. As a result, each single-pole coil can move while keepingits coil insertion portions at the minimum distance at all times. Fromthis point, it is unnecessary to add excessive length to the coil endportions.

Noting all the single-pole coils 8 of one phase, moreover, all the coilinsertion portions 801 start their movements simultaneously and move atthe equal velocities. As a result, the length of the crossover lines andthe coil length can be minimized, and the movements of the coilinsertion portions 801 are well balanced. Therefore, the coils are notdisturbed in their arrayed state and the electric lines (or the wires)constructing the coils are hardly damaged.

Especially in this embodiment, moreover, the provisional shaping grooves24 are formed in the magazine 2 so that the provisional shaping isperformed by the movements of the provisional shaping blades 34. As aresult, the provisional shaping can be easily performed to push anddeform the coil end portions 802 of the coil outward, each time eachsingle-pole coil 8 is mounted in the stator core 1. Moreover, theseworks can be done simultaneously with the transfer of the coils, therebyto simplify the device and the step.

In this embodiment, moreover, the formers 66 are used and pushed ontothe stator core 1 to perform the second provisional shaping and theproper shaping of the coils 2. As a result, all the provisionally shapedcoils can be shaped all at once into a desired shape merely by pushingthe formers 66 onto the stator core 1. By the second provisional shapingand the proper shaping, moreover, the coil end portions bulging from thestator core 1 can be shaped to approach the stator core 1 so that theaforementioned axial size can be made smaller.

Moreover, the formers 66 are provided with the aforementioned cutouts sothat they can be pushed onto the stator core 1 while the insertionblades 3 and the provisional shaping blades 34 are advanced. Therefore,the second provisional shaping and the proper shaping by the formers 66can be executed consecutively during the insertion and provisionalshaping of the coils 8 into the stator core 1, as describedhereinbefore, so that the manufacturing process can be rationalized.

Here in this embodiment, the insertion blades 3 are used as an exampleof a coil inserting means, and the provisional shaping blades 34 areused as an example of a provisional shaping means. However, these bladescould be replaced by the split insertion blades or the split insertionhooks and the split provisional shaping blades or the split provisionalshaping hooks, which are split on the surface side face and the backside face of the magazine 2. In this modification, moreover, the splitinsertion blades or the split insertion hooks and the split, provisionalshaping blades or the split provisional shaping hooks could beintegrated on the surface side face and the back side face of themagazine 2, thereby to simplify the device.

Moreover, this embodiment has exemplified the three-phase DC brushlessmotor, but process thus far described could be applied to a motor ofanother structure.

In a second embodiment of the invention, a coil inserting apparatus forinserting the coils from the magazine 2 of Embodiment 1 into the stator1 is shown in more detail in FIG. 18 and FIG. 19.

The coil inserting apparatus 9 of this embodiment is, as shown FIG. 18,provided with an upper plate portion 92, which is fixed through thenot-shown posts extended from a bottom plate portion 91, and a magazinereceiving rest 93 disposed above the upper plate portion 92 for placingthe magazine 2 thereon.

The magazine receiving rest 93 is composed of a flange portion 931, anda central mandrel 932 having a column shape with a smaller diameter thanthat of the flange portion 931.

Moreover, the bottom plate portion 91 is provided with a plurality offirst arms 94 arranged to rock on fulcrums 941, and a plurality ofsecond arms 95 arranged to rock on fulcrums 951. As shown in the sameFigure, the first arms 94 are provided with the insertion blades 3 attheir upper ends, and the second arms 95 are provided with theprovisional shaping blades 34 at their upper ends.

The first arm 94 is provided with a slot 942, which can engage with apin 963 formed on a lifting plate 961. As shown in FIG. 18, on the otherhand, the second arm 95 is provided with a slot 952, which can engagewith a pin 964 formed on a second lifting plate 962.

Moreover, the lifting plate 961 is connected to a cylinder 971, alifting rod 972, a base plate 973, a connecting rod 974 and so on, whichare arranged above the bottom plate portion 91, so that it is moved upand down as the lifting rod 972 is driven upward and downward by thecylinder 971.

Moreover, the slots 942 and 952 formed in the first arm 94 and thesecond arm 95 have sloped slot portions. As the engaging positionsbetween the pins 963 and 964 and the slots 942 and 952 are shifted bythe vertical movements of the pins 963 and 964, moreover, the first arm94 and the second arm 95 rock on the fulcrums 941 and 951. Here, theshapes of the slot 942 of the first arm 94 and the slot 952 of thesecond arm 95 are slightly changed to give different rocking strokes tothe first arm 94 and the second arm 95.

As shown in FIG. 19, moreover, each first arm 94 is arranged with thetwo insertion blades 3 in parallel so that these two insertion blades 3are moved together in parallel in the rocking direction of the first arm94. Here, the rocking directions of all the first arms 94 are takenalong a radial direction A through the center of teeth 15 positionedbetween the two slots 10 of the stator 1.

Moreover, each second arm 95 is likewise arranged with the twoprovisional shaping blades 34 in parallel so that these two provisionalshaping blades 34 are moved together in parallel in the rockingdirection of the second arm 95. Here, the rocking directions of all thesecond arms 95 are taken along a radial direction B through the centerof the teeth 15 positioned between the two slots 10 of the stator 1.

What should be noted on this coil inserting apparatus 9 is that theangle of inclination α of the insertion blades 3 at the rocking motionstarting position of the insertion blades 3 with respect to the verticaldirection is set within 5 degrees, and that the angle of inclination atthe rocking motion ending position with respect to the verticaldirection is set at 0 degrees, as shown in FIG. 18.

When the coils are to be transferred from the magazine 2 to the stator 1by using the coil inserting apparatus 9, therefore, all the single-polecoils 8 can be simultaneously moved generally linearly toward the statorcore 1 while the angle made between the coil insertion portions 801 toabut against the insertion blades 3 and the slots 10 of the stator 1being always kept within 5 degrees.

As described hereinbefore, moreover, the two adjoining insertion blades3 are arranged in parallel and push the adjoining coil insertionportions 801 of the adjoining single-pole coils 8. As a result, theadjoining coil insertion portions 801 can be pushed by the insertionblades 3 to move in parallel in the two coil retaining grooves 20arranged in parallel, as described hereinbefore, and the pushing pointsare always kept in parallel. And, the adjoining coil insertion portions801 of the adjoining single-pole coils 8 can be moved remarkably easilyin parallel with each other until they reach the slots 10, thereby tomake their moving loci parallel.

In a third embodiment of the invention, another example of theaforementioned insertion blades is shown in FIGS. 20A and 20B. As shownin FIGS. 20A and 20B, specifically, an insertion blade 302 of thisembodiment is formed into a generally L-shape, which is composed of ahorizontally extending base portion 303 and a vertically extendingvertical blade portion 304. Moreover, this vertical blade portion 304has an abutment face 305 formed as a vertical face. And, the insertionblade 302 is constructed such that the vertical blade portion 304 ismoved back and forth by moving the base portion 303 horizontally withits abutment portion 305 being kept vertical.

By using this insertion blade 302, the angle made between the coilinsertion portion 801 and the axial direction of the slot core 1 can bekept substantially at 0, as shown in FIG. 20A, not only at the time ofabutting against the coil insertion portion 801 but also at the instantwhen the insertion of the stator core 1 into the slots 10 is completed.

As shown in FIGS. 21A-22C, this fourth embodiment of the invention usesa pair of upper and lower split insertion blades 320 and 330 as theinsertion blades.

Specifically, the split insertion blades 320 and 330 of this embodimentare a pair of upper and lower strip shapes, as shown in FIGS. 21A-22C,and have such tapered portions 325 and 335 on one-side faces of theirleading end sides as are arranged to have their leading ends in aconfronting relation.

Next, the actions of the split insertion blades 320 and 330 of the casein which the single-pole coils 8 are moved will be briefly describedwith reference to FIGS. 21A-22C. FIGS. 21A-21C present views, in whichthe motions of the split insertion blades 320 and 330 and thesingle-pole coils 8 are taken in the radial direction of the stator core1. FIGS. 22A-22C present explanatory views, which correspond to theindividual actions of FIG. 21 and in which the width sizes of theportions, as contacting with the coils 8, of the split insertion blades320 and 330, are taken and shown in the axial direction of the statorcore 1.

As FIG. 21 and FIG. 22 proceed from (a) to (c), the split insertionblades 320 and 330 approach and overlap each other. The width sizes ofthe abutting portions against the single-pole coils 8 grow graduallylarger along the tapered portions 325 and 335 so that the single-polecoils 8 are gradually pushed into the slots 10 of the stator core 1.

Here, the insertion pressure to be applied to the single-pole coil 8 isapplied to the four portions which are generally symmetric with respectto the winding center point of the single-pole coil 8, as will be shownin FIG. 29 described herein after. As a result, the single-pole coil 8can be moved linearly from the state, in which it is arranged generallyin parallel with the slot 10, while substantially maintaining theposture of the singer-pole coil 8.

As shown in FIG. 23 to FIG. 25, this fifth embodiment of the inventionadopts a magazine 202 having a structure different from that of thefirst Embodiment.

The magazine 202 of this embodiment has supporting rod portions 203 forforming coil retaining grooves to retain the single-pole coils 8. Inthis case, too, the coil inserting step can be executed as in the firstEmbodiment by retaining the single-pole coils 8 in the manner shown inFIG. 23 and FIG. 24.

As shown in FIG. 26 to FIG. 28, too, this sixth embodiment of theinvention adopts a magazine 204 having a construction different fromthat of the magazine of the first embodiment.

The magazine 204 of this embodiment is provided with a pair of upper andlower magazine plates 205 for every one pole, which extend from theradially outer side to the inner circumference side.

In this case, as shown in FIG. 26 to FIG. 28, the single-pole coils 8 ofone pole are retained by the magazine plates 205 of the magazine 204 andare mounted up and down in the axial direction of the stator core 1. Thesingle-pole coils 8 are pushed and moved in the slots 10 by theinsertion blades or the like. After this, the coil inserting step can beexecuted by the actions to extract the magazine plates 205 retaining theindividual single-pole coils 8, either one by one or simultaneouslytogether to the radially outer side.

As shown in FIG. 29 to FIG. 34, this seventh embodiment of the inventionpresents an example of the position, at which the insertion pressure isapplied to the single-pole coil 8 at the coil inserting step.

FIG. 29 shows an example, in which the insertion pressure is applied toa plurality of positions substantially symmetric with respect to thewinding center point of the single-pole coil 8. That is, the pushedregions F of four corners at the boundary portions between the coilinsertion portions 801 and the coil end portion 802 of the single-polecoil 8.

FIG. 30 shows an example, in which the insertion pressure is applied toa plurality of positions substantially symmetric with respect to thewinding center point of the single-pole coil 8. That is, pushed regionsF of two diagonal ones of the four corners at the boundary portionsbetween the coil insertion portions 801 and the coil end portion 802 ofthe single-pole coil 8.

FIG. 31 and FIG. 34 show an example, in which the insertion pressure isapplied to the pushed regions F of the two coil end portions 802 of thesingle-pole coil 8, individually.

FIG. 32 and FIG. 33 show an example, in which the insertion pressure isapplied to the pushed regions F of the two coil insertion portions 801of the single-pole coil 8, individually.

According to any of these examples, the single-pole coil 8 can belinearly moved while the angle made between the coil insertion portions801 of the single-pole coil 8 and the slots 10 is kept within 5 degrees.Here, FIG. 29 to FIG. 34 just present the examples, and it is quitenatural that the pushed regions F or the applied positions of theinsertion pressure could be further modified.

As shown in FIG. 35 and FIG. 36, this eighth embodiment of the inventionpresents an example, in which split insertion hooks can be used as anexample of a coil inserting means in place of the insertion blades 3 ofthe first embodiment.

FIG. 35 shows one of a pair of split insertion hooks 350, which aresplit into the surface side and the back side of the magazine. Thesesplit insertion hooks 350 have an L-shaped section to be hooked on thetwo end portions of the coil end portion 801 so that they apply theinsertion pressure to the pushed regions F of the four corners, as shownin FIG. 29.

FIG. 36 shows one of a pair of split insertion hooks 352, which aresplit into the surface side and the back side of the magazine. Thesesplit insertion hooks 352 have a C-shaped section to be hooked on theentirety of the coil end portion 801 so that they apply the insertionpressure, as shown in FIG. 34. The coil inserting step like that of thefirst embodiment can also be executed by using those split insertionhooks.

In the ninth embodiment of the invention, as shown in FIG. 37 to FIG.55, the coil forming step is executed by using a magazine (or a take-upjig) 7, which has a special structure to function as the take-up jig.

In this embodiment, there are used the take-up jig (or the magazine) 7and a turning device 74 are used as a coil forming device for forming amotor coil (as referred to FIG. 50), which is prepared by juxtaposingthree adjacent single-pole coils 8 turned in a loop shape with theelectric line 88, as shown in FIG. 37 and FIG. 38.

As shown in FIG. 37 to FIG. 39, the take-up jig 7 is provided with abase holder 70 and a plurality of winding frames 4 arranged on the outercircumference of the base holder 70. The individual winding frames 4 arearranged to move to and from the base holder 70 and are constructed suchthat any of the winding frames 4 may protrude from the remaining ones.

As shown in FIG. 37 and FIG. 38, the turning device 74 is constructed toturn the take-up jig 7 as a whole on the longitudinal axis C of thewinding frame 4 protruded.

The coil forming device of this embodiment will be described in detailin the following. In the take-up jig 7, as shown in FIG. 39, the baseholder 70 has a disc shape. Specifically, the base holder 70 has a pairof upper and lower ring-shaped plates 71 and 72, which are provided withcentral through holes 710 and 720, respectively, and a plurality ofpositioning holes 712 and 722 around the central through holes 710 and720. These central through holes 710 and 720 and the positioning holes712 and 722 are provided for determining the engaging positions with theturning device 74, as will be described hereinafter.

Moreover, the paired upper and lower ring-shaped plates 71 and 72 areconnected through separate plates 79, which are arranged in the radialdirection extending from the centers of those ring-shaped plates 71 and72. In this embodiment, the four separate plates 79 are arranged at apitch of an internal angle of 15 degrees, and the four separate plates79 are further arranged at the diagonal positions at the pitch of theinternal angle of 15 degrees. In the spaces of the internal angle ofabout 15 degrees between the adjoining separate plates 79, moreover,there are individually arranged the winding frames 4. In thisembodiment, the six winding frames 4 in total are provided by arrangingthe three adjoining winding frames 4 at the diagonal positions.

Here, as shown in FIG. 39, the take-up jig 7 of this embodiment isconstructed such that the separate plates 79 and the winding frames 4can be further arranged at empty positions in the outer circumference ofthe disc-shaped base holder 70, so that it can be provided with thetwelve winding frames 4 at the maximum.

As shown in FIG. 39, moreover, the winding frames 4 are arranged suchthat they can move back and forth along the axes extending radially fromthe center point of the base holder 70. Moreover, the individual windingframes 4 have a sector shape, in which they are widened along theaforementioned axis.

As shown in FIG. 39, more specifically, each winding frame 4 has a framebody portion 42, which is generally formed in a sector shape in view ofthe front face and the back face, if these front and back faces arethose parallel to the ring-shaped plates 71 and 72 of the base holder70, and which is provided with a cutout 420 at its central portion.Moreover, the frame body portion 42 is provided on its two side faceswith stepped portions 425 for positioning the formed single-pole coil 8.

On the front side and the back side of the frame body portion 42, on theother hand, there are removably arranged shaping blocks 43 and 44 forprofiling the shapes of the single-pole coil to be wound. These shapingblocks 43 and 44 are also generally formed in a sector shape, which isprovided with cutouts 430 and 440 at their central portions. Here, theshaping blocks 43 and 44 are fixed on the frame body portion 42 bydriving the not-shown screws.

As shown in FIG. 39, moreover, the shaping blocks 43 and 44 of thisembodiment are made the thicker as they come the closer to the innercircumference side from the outer circumference side, so that thesingle-pole coil to be shaped may become higher toward the innercircumference side.

As shown in FIG. 39, moreover, the frame body portion 42 is providedwith a rectangular through hole 429 in the axial direction from thecutout 420 to the base holder 70. In the upper and lower portions of thethrough hole 429, moreover, rod holes 428 are formed as circular throughholes. Moreover, the winding frame 4 is arranged to move back and forthin the base holder 70 by fixing a guide plate 41 through the throughhole 429 in the base holder 70.

As shown in FIG. 39, more specifically, the guide plate 41 is providedwith a root end portion 415 to be fixed in the base holder 70, and aleading end portion 410, which is vertically large-sized generally in aT-shape to regulate the advanced position of the winding frame 4. And,the root end portion 415 of the guide plate 41 is inserted into thethrough hole 429 opened in the bottom portion of the cutout 420 of theframe body portion 42, and rods 45 carrying springs 46 are inserted intothe rod holes 428 formed at the upper and lower portions of the throughhole 429 in the frame body portion 42. And, the root end portion 415 ofthe guide plate 41 is clamped and fixed between the paired upper andlower ring-shaped plates 71 and 72 of the base holder 70, and the tworods 45 are fixed at their one-side ends on the ring-shaped plates 71and 72 and at their other ends on the leading end portion 410 of theguide plate 41. As a result, the winding frame 4 is fixed such that itcan move back and forth with respect to the base holder 70.

As shown in FIG. 51 to FIG. 53, moreover, the winding frame 4 isprovided in its upper and lower portions with positioning pins 48, whichcan move their leading end portions 481 forward and backward by pinchingand operating their head portions 480. Moreover, the guide plate 41 isprovided with pin holes 418 and 419, which can engage with the pinleading end portions 481. While the pin leading end portions 481 of thepositioning pins 48 being made to engage with the pin holes 418, asshown in FIG. 51, the winding frame 4 is retracted and kept in the stateclose to the base holder 70. When the winding frame 4 is to be advanced,on the other hand, the positioning pins 48 are retracted to release thepin leading end portions 481 and the pin holes 418 from the engagingstate so that the winding frame 4 is advanced against the springs 46. Asshown in FIG. 53, moreover, the positioning pins 48 are advanced againto bring the pin leading end portions 481 into engagement with the pinholes 419. As a result, the winding frame 4 is advanced in its axialdirection and is fixed at a position spaced from the base holder 70.

On the two sides of each winding frame 4 thus arranged, there exists theseparate plates 79, which are extended from the outer circumference ofthe base holder 70. Moreover, the separate plate 79 and the windingframe 4 are spaced at a predetermined distance functioning as thelater-described coil retaining groove 20.

Of the coil retaining grooves 20, as shown in FIG. 40, there arearranged in parallel the coil retaining grooves (e.g., 20A2 and 20B1, or20B2 and 20C1 in FIG. 40) for arranging the adjoining coil insertionportions 801 in the adjoining single-pole coils 8.

In the take-up jig 7 of this embodiment, moreover, the contour formed ofthe leading ends of all the winding frames 4 retracted is a circularshape around the center point of the base holder 70. In other words, thetake-up jig 7 of this embodiment is shaped such that the individualwinding frames 4 may be arranged to confront the inner circumference ofthe later-described stator core.

Next, as shown in FIG. 37 and FIG. 38, the turning device 74 of thisembodiment is provided with a straight portion 741 extending from thenot-shown drive shaft, and a bent portion 76 connected to the straightportion 741 through flanges 751 and 752, and the bent portion 76 isprovided at its leading end with a flange 77 for connecting the bentportion 76 to the take-up jig 7.

As shown in the same Figures, the bent portion 76 is provided with: afirst portion 761 extending on the common axis of the straight portion741; a second portion 762 bent at 90 degrees and extended from the firstportion; a third portion 763 bent at 90 degrees from the second portion762 and extended in parallel with the straight portion 741; and a fourthportion 764 bent at 90 degrees from the third portion 763. And, theaforementioned connecting flange 77 is arranged at the leading end ofthe fourth portion 764.

When the connecting flange 77 is connected to the base holder 70 of thetake-up jig 7, as shown in FIG. 37 and FIG. 38, the connecting flange 77is so positionally arranged that the center point of the base holder 70in the thickness direction and in the radial direction may be located onthe axis of the straight portion 741.

Moreover, the circumferentially fixed position of the connecting flange77 to the take-up jig 7 can be so suitably changed that the axis C ofthe winding frame 4 may be aligned with the turning center C2 of thestraight portion 741 of the turning device 74.

With reference to FIG. 40 to FIG. 50, here will be described a processfor forming a motor coil having a plurality of juxtaposed single-polecoils 8, by the coil forming apparatus including the take-up jig 7 andthe turning device 74 thus far described. The presentation of theturning device 74 is omitted from those Figures.

First of all, all the winding frames 4 in the take-up jig 7 areretracted, as shown in FIG. 40, and the take-up jig 7 is so fixed on theturning device 74 that the turning center C2 (as referred to FIG. 37 andFIG. 38) of the turning device 74 is aligned with the axis C of thefirst winding frame 4 a.

Next, a winding frame protruding step is performed to advance the firstwinding frame 4 a from that state so as to protrude the same from theremaining winding frames 4, as shown in FIG. 41. At this time, thewinding frame 4 a is released from the fixed state, in which it is fixedat the retracted position by the positioning pins 48 (FIG. 51 to FIG.53), and the winding frame 4 a is advanced against the springs 46. Thewinding frame 4 a is fixed again at its advanced position by thepositioning pins 48.

Then, the electric line 88 is fed in one direction from above, as shownin FIG. 41, and its leading end is fixed on the take-up jig 7. In thisfixing method, a special fixing device may be used to fix the leadingend at a predetermined position, or the leading end may be tied to anarbitrary position of the take-up jig 7. The latter method is adopted inthis embodiment.

Next, as shown in FIG. 41 and FIG. 42, the protruded winding frame 4 ais fed in one direction with the electric line 88, and the turningdevice 74 is driven to perform a winding step of turning the take-up jig7 as a whole on the axis C of the winding frame 4 a. As a result, theelectric line 88 is wound around the protruded winding frame 4 a,thereby to complete the formation of the first single-pole coil 8, asshown in FIG. 43.

Next, there is performed a winding frame retracting step of retractingthe first winding frame 4 a having the single-pole coil 8 formedthereon, as shown in FIG. 44. At this time, the winding frame 4 a isfixed at the retracted position by operating the positioning pins 48(FIG. 51 to FIG. 53) again.

As shown in FIG. 44, the single-pole coil 8 wound around the windingframe 4 a takes the state, in which its coil end portions 802 positionedabove and below the loop are uncovered to the surface side and back sideof the winding frame 4 and in which the coil insertion portions 801positioned on the left and right are housed in the clearances betweenthe separate plates 79 and the winding frame 4.

Next, as shown in FIG. 45, a second winding frame 4 b adjacent to thefirst winding frame 4 a having the single-pole coil 8 formed thereon isadvanced along the axis C to protrude from the outer sides of theremaining winding frames 4 and is fixed like before at the advancedposition.

Before or after this winding frame protruding step, moreover, theengaging position between the take-up jig 7 and the turning device 74 ischanged to align the turning center of the turning device 74 and theaxis of the second winding frame 4 b.

As shown in FIG. 45, a crossover line 885 leading from the single-polecoil 8 retained by the first winding frame 4 a is turned over to belowthe second winding frame 4 b, and the succeeding electric line 88 is fedlike before from above in one direction.

Next, as shown in FIG. 45 and FIG. 46, the protruded winding frame 4 bis fed with the electric line 88 in one direction, and there isperformed the winding step of turning the take-up jig 7 as a whole onthe axis C of the winding frame 4 b. The turning direction at this timeis reversed from that of the case of the first winding frame 4 a. As aresult, the electric line 88 is wound around the protruded winding frame4 b, as shown in FIG. 47, thereby to complete the formation of thesecond single-pole coil 8 having its wound direction reversed from thatof the first single-pole coil 8.

Next, as shown in FIG. 47, the second winding frame 4 b having thesingle-pole coil 8 formed thereon is retracted and is fixed like beforeat the retracted position. The second single-pole coil 8 wound aroundthe winding frame 4 b takes the state, in which its coil end portions802 positioned above and below the loop are uncovered to the surfaceside and back side of the winding frame 4 and in which the coilinsertion portions 801 positioned on the left and right are housed inthe clearances between the separate plates 79 and the winding frame 4.

Next, as shown in FIG. 48, a third winding frame 4 c adjacent to thesecond winding frame 4 b is advanced along the axis C to protrude fromthe outer sides of the remaining winding frames 4 and is fixed likebefore at the advanced position. In this case, too, before or after thiswinding frame protruding step, moreover, the engaging position betweenthe take-up jig 7 and the turning device 74 is changed to align theturning center C2 (FIG. 37 and FIG. 38) of the turning device 74 and theaxis C of the third winding frame 4 c.

As shown in the same Figure, the electric line 88 succeeding to thecrossover line 885 leading from the single-pole coil 8 retained by thesecond winding frame 4 b is fed like before from above in one direction.

Next, as shown in FIG. 48 and FIG. 49, the protruded winding frame 4 cis fed with the electric line 88 in one direction, and there isperformed the winding step of turning the take-up jig 7 as a whole onthe axis C of the winding frame 4 c. The turning direction at this timeis reversed from that of the case of the second winding frame 4 c. As aresult, the electric line 88 is wound around the protruded winding frame4 c, as shown in FIG. 49, thereby to complete the formation of the thirdsingle-pole coil 8 having its wound direction reversed from that of thesecond single-pole coil 8.

Next, as shown in FIG. 50, the third winding frame 4 c having thesingle-pole coil 8 formed thereon is retracted and is fixed like beforeat the retracted position. The coil insertion portions 801 of the thirdsingle-pole coil 8 formed around the winding frame 4 c are also housedin the clearances between the separate plates 79 and the winding frame4.

As a result, there is completed the coil, in which the three single-polecoils 8 are juxtaposed to each other such that their winding directionsare alternately reversed.

Next, as shown in FIG. 50, for three winding frames 4 d to 4 f opposedto the three winding frames 4 a to 4 c having the aforementioned coilsformed, too, the coil, in which the three single-pole coils 8 arejuxtaposed to each other with the alternately reversed windingdirections can be formed by a procedure similar to the aforementionedone.

Thus in the coil forming method of this embodiment, there are used thetake-up jig 7 having the aforementioned structure composed of the baseholder 70 and the winding frames 4 and the turning device 74. Asdescribed hereinbefore, moreover, the winding frame protruding step, thewinding step and the winding frame retracting step are performedsequentially on the individual winding frames.

Here, the winding step is performed by turning the take-up jig as awhole on the axis C of the protruded winding frame 4. As describedhereinbefore, therefore, the electric line 88 can be fed in onedirection so that the single-pole coil 8 can be formed around thewinding frame 4 without any torsion of the electric line 88.

On the other hand, the winding step follows the winding frame protrudingstep, and is followed by the winding frame retracting step. In case thewinding frame 4 or the object of the winding step is to be changed, morespecifically, this change can be made by advancing and retracting thewinding frame 4 at the winding frame protruding step and at the windingframe retracting step, and no special space for feeding the electricline need be established between the adjoining winding frames 4.Therefore, the length of the crossover line 885 between the single-polecoils 8 obtained can be reduced to a sufficient short length.

In this embodiment, moreover, each winding frame 4 of the take-up jig 7is generally given the sector shape, and the shaping blocks 43 and 44are arranged on the surface side and back side of the winding frame 4.The shaping blocks 43 and 44 are thickened in the inward direction asdescribed above. In the single-pole coil 8 wound around the windingframe 4, therefore, the shapes of the electric line loops composingitself are changed along the axis C of the winding frame 4.

Specifically, the electric line loops composing the single-pole coil 8become wider in the outward direction along the sector-shaped windingframe 4 and become lower along the shape of the shaping blocks 43 and44. As a result, it is possible to optimize the arrangement of the coilend portions 802, as will be described hereinafter, when the coil ismounted on the stator core. By adopting this structure, in which thewidth is larger from the radially inner side to the outer side and inwhich the axial height is smaller from the radially inner side to theouter side, it is possible to prevent the shifts of the individualelectric lines (or the coils) composing the single-pole coil 8 at thetime of taking up the electric line 88.

In the take-up jig 7 of this embodiment, moreover, the contour formed ofthe leading ends of all the winding frames 4 retracted is the circularshape so that the individual winding frames 4 can be arranged toconfront the inner circumference of the later-described stator core.

On the two sides of each winding frame 4, moreover, there exists theseparate plates 79, which are extended from the outer circumference ofthe base holder 70. Moreover, the clearance between the separate plate79 and the winding frame 4 functions as the coil retaining groove 20. Asexemplified in the second embodiment, the individual single-pole coils 8can be mounted on the stator core by their linear movements along thosecoil retaining grooves.

Next, here will be presented an embodiment of a method of inserting thecoil formed by using the coil forming apparatus, directly from thetake-up jig 7 into the stator core.

In this embodiment, as shown in FIG. 54 and FIG. 55, the coils (asreferred to FIG. 50) are inserted and arranged in the slots 10 which areformed in the inner circumference of the ring-shaped stator core 1. Inthis embodiment, here are omitted the coils (or the single-pole coils 8)so as to clarify the movements of the later-described insertion blades3.

The motor to be constructed by using the stator core 1 is thethree-phase DC brushless motor. And, the stator core 1 in thisembodiment is manufactured by laminating the ring-shaped electromagneticsteel sheets, and is provided in its inner circumference with the slots10 for inserting the coils, as shown in FIG. 54 and FIG. 55.

In this embodiment, the stator core 1 is provided with the seventy twoslots 10 so as to arrange the thirty six single-pole coils 8 in total.And, every twelve single-pole coils 8 bears each phase. In thisembodiment, as described hereinbefore, two sets of coils having threesingle-pole coils 8 are prepared by the single take-up jig 7, and aresimultaneously mounted in the stator core 1. By performing these workssix times, all the single-pole coils 8 needed are mounted in the statorcore 1.

These works will be described more specifically. First of all, thetake-up jig 7 is so arranged in the stator core 1 that coil retaininggrooves 790, as formed between the winding frame 4 and the separateplate 79, in the take-up jig 7 may confront the slots 10 of the statorcore 1, as shown in FIG. 54.

As shown in FIG. 54, moreover, the insertion blades 3 are inserted intothe coil retaining grooves 790 of the take-up jig 7. In the take-up jig7, moreover, the cutouts 420 formed in the frame body portion 42 of thewinding frame 4 and the cutouts 430 and 440 (as referred to FIG. 39)formed in the upper and lower shaping blocks 43 and 44 provideprovisional shaping grooves 795, into which the provisional shapingblades 34 are to be inserted.

As shown in FIG. 55, moreover, the insertion blades 3 are advanced inthe coil retaining grooves 790 in the direction from the center to theouter circumference. Simultaneously with this, the provisional shapingblades 34 are advanced in the provisional shaping grooves 795 in thedirection from the center to the outer circumference. As a result, thesingle-pole coils 8 are pushed by the insertion blades 3 to movegenerally linearly from the coil retaining grooves 790 to the slots 10of the stator core 1. On the other hand, the upper and lower coil endportions 802 (FIG. 50), as bulging from the stator core 1, in thesingle-pole coil 8 is subjected to a provisional shaping treatment, inwhich they are pushed and deformed outward by the provisional shapingblades 34.

These advancing actions of the insertion blades 3 and the provisionalshaping blades 34 are simultaneously done on all the six single-polecoils 8 so that these six single-pole coils 8 are simultaneouslyinserted into the slots 10 of the stator core 1.

Next, in this embodiment, a second provisional shaping is executed byusing the paired upper and lower formers 66 (as referred to FIG. 12)like those of the first embodiment. The formers 66 have ring shapes, asdescribed hereinbefore, and are provided, on their sides confronting thestator core 1, with the shaping faces 660 for profiling the coils into adesired shape. Moreover, each former 66 is provided with cutouts 665 forpreventing the insertion blades 3 and the provisional shaping blades 34from interfering each other. And, the formers can be pushed onto thestator core 1 while the insertion blades 3 and the provisional shapingblades 34 being advanced.

The paired upper and lower formers 66 thus constructed are individuallyadvanced from their upper and lower positions and pushed onto the statorcore 1. As a result, the second provisional shaping is performed suchthat the coil end portions 802, as bulging out from above and below thestator core 1, of the six single-pole coils 8 thus arranged in thestator core 1 fall down toward the stator core 1.

Next, in this embodiment, the aforementioned coil forming apparatus isused to form two sets of coils having three single-pole coils 8, newlyon the take-up jig 7. Like before, moreover, there are performed themovement of the coils from the take-up jig 7 directly to the stator core1, the provisional shaping and the final second provisional shaping. Byrepeating these works six times in total, the thirty six single-polecoils 8 in total are mounted on the stator core 1. And, the shaping tobe performed as the second provisional shaping by the formers isperformed on all the thirty six single-pole coils 8 so that it becomesthe proper shaping step for profiling the entire coil shape. Thus, thethirty six single-pole coils 8 in total are inserted and arranged in thestator core 1.

Here in this embodiment, a series of works are performed from theformation of the six single-pole coils to the second provisional shapingand are repeated six times. However, the efficiency can be enhanced byusing a plurality of sets of take-up jigs 7. Moreover, the steps can berationalized by increasing the number of winding frames 4 in the take-upjig 7 from six to twelve and by moving the twelve single-pole coils 8all at once to the stator core 1.

By making use of the take-up jig 7 and the insertion blades 3, asdescribed hereinbefore, this embodiment can also execute the so-called“linear insertion method”, by which the coils are linearly moved, easilyand stably. Moreover, the coil retaining grooves 20, which are formedbetween the winding frames 4 and the separate plates 79, are parallel toeach other for arranging the adjoining coil insertion portions 801 ofthe adjoining single-pole coils 8. As in the first embodiment,therefore, it is possible to ensure the parallel moving loci of the coilinsertion portions 801 before inserted into the slots 10. And, thesingle-pole coils 8 can be linearly inserted without changing theirpostures into the slots 10. Therefore, it is not necessary to enlargethe vertical length of the coils more than necessary.

In this embodiment, moreover, the coils can be moved from the windingframes 4 having formed them, directly to the stator core 1, as describedhereinbefore. Moreover, the coils need not be transferred, after formed,from the winding frames to another coil transfer device so that thecoils can be highly efficiently mounted on the stator core. This isbecause the take-up jig 2 has the aforementioned excellent structure, asdetailed hereinbefore.

Moreover, the coils can be inserted from the take-up jig 7 directly intothe stator core 1 so that their movements can be easily executed even ifthe crossover lines connecting the single-pole coils 8 are short.

In the tenth embodiment of the invention, a wedge inserting step isexecuted after completion of the coil inserting step of the firstembodiment.

The slot 10 of the stator core 1 of this embodiment is provided, asshown in FIG. 57, with a slot open portion 102, which has its spaceportion constricted at its inner circumference end portion, and ageneral portion 101 which has a wider space than that of the slot openportion 102 on its outer circumference side.

After the coil inserting step, moreover, the wedge inserting step isperformed to insert a wedge 901 into the slot 10 thereby to clog theinner circumference open portion in the slot 10.

The wedge 901 is provided, as shown in FIG. 56, with a wide portion 911arranged in the general portion 101 of the slot 10, and a convex portion912, which has a smaller width size than that of the wide portion 912,which is protruded from the wide portion 911 and which is arranged inthe slot open portion 102. This will be described in detail in thefollowing.

The stator core 1 in this embodiment has a ring shape and is provided atits inner circumference portion with a plurality of teeth 105, as shownin FIG. 57, to form the slot 10 in between. Each tooth 105 extendsradially from the outer circumference side to the inner circumferenceside and is provided at its leading end portion with protrusions 106protruding in the circumferential directions. The space, at which thoseprotrusions 106 confront each other, is the aforementioned slot openportion 102 in the slot 10, and the space on the outer circumferenceside is the aforementioned general portion 101.

In this embodiment, moreover, there is arranged in advance all over theinner circumference of the slot 10 an insulating film 107, which is madeof a synthetic resin having electrically insulating properties, as shownin FIG. 57. Specifically, a film made of an LCP (Liquid Crystal Polymer)is formed in advance. In this embodiment, the insulating film 107 is setto have a thickness of about 300 microns. Here, a sheet of electricallyinsulating aramid fibers of the prior art can also be applied to thatinsulating film 107.

As shown in FIG. 56, the wedge 901 is made of an LCP (Liquid CrystalPolymer) and is formed into an integral shape having the wide portion911 and the convex portion 912. This convex portion 912 has a heightsize H1 slightly smaller than the radial size of the slot openingportion 102, i.e., the thickness size of the tooth 105. Moreover, thewidth sizes W1 and W2 of the convex portion 912 and the wide portion 911are so designed to correspond to the sizes of the space widths of theslot open portion 102 and the general portion 101 of the slot 10 as toestablish a small clearance (although not shown) between the confrontingteeth 105.

This clearance is sized to be sufficiently smaller than both the size L(FIG. 57) of the protrusion of the inner wall face forming the slot openportion 102 in the stator core 1 from the inner wall face forming thegeneral portion and the diameter D (FIG. 57) of the electric lineforming the coil to be inserted and arranged in the slot 10.

Here, it is preferred, as described hereinbefore, for improving theinserting works that a small clearance is formed in the design betweenthe wedge 901 and the tooth 105. In order that the convex portion 912may play the role to prevent the turning of the wedge 901, however, thatclearance should be as small as possible. It is most desired that thewedge 901 contacts in face-to-face relation with the tooth 105 when itis mounted.

Next, the works to insert the wedges 901 into the slots 10 of the statorcore 1 are done after all the single-pole coils 8 were inserted into theslots 10. In this embodiment, as in the first embodiment, there isperformed a linear inserting method (or a radial inserting method) ofmoving the single-pole coils 8, as formed by winding the wire 88 inadvance, generally linearly from the inner circumference side of thestator core 1 into the slots 10. After this, the wedges 901 are insertedaxially into the inner circumference openings of the slots 10.

At this time, the wedges 901 are so inserted into the slots 10 thattheir convex portions 912 are positioned on the inner circumference sideof the stator core 1 whereas the wide portions 911 are positioned on theouter circumference side, and such that those portions 912 and 911correspond to the slot open portions 102 and the general portions 101 ofthe slots 10.

As a result, as shown in FIG. 57, the inner circumference openings ofthe slots 10 can be reliably clogged such that the wide portions 911 andthe convex portions 912 of the wedges 901 are positioned in the generalportions 101 and the slot open portions 102 of the slots 10,respectively.

The wedge 901 of this embodiment has a shape composed of the wideportion 911 and the convex portion 912, as described hereinbefore, sothat it is shaped to have a far superior rigidity than that of the wedgeof the prior art, which is formed by bending a sheet-shaped material.Therefore, the wedge has such a strength as can stand sufficiently, evenin case the wedge 901 is solely inserted after the single-pole coil 8was inserted by the radial inserting method into the slot 10 of thestator core 1. By making use of the improved rigidity of the wedge 901,moreover, it is possible to make the width of the slot open portionwider than that of the prior art. Therefore, the radial inserting methodcan be more stably executed to rationalize the manufacturing process.

Moreover, the wide portion 911 and the convex portion 912 of the wedge901 are arranged in the general portion 101 and the slot open portion102 of the slot 10 of the stator core 1, respectively, as describedhereinbefore. As a result, the convex portion 912 engages with the slotopen portion 102 so that the wedge 901 can be prevented from turning andcoming out of the slot open portion 102. Therefore, it is possible tokeep the stable clogged state of the inner circumference opening 109 ofthe slot 10.

In the eleventh embodiment of the invention, one example of the workingmethod of inserting the wedge 901 of the tenth embodiment into the slot10 will be described further in detail. In this embodiment, as shown inFIG. 58, there is used an insertion apparatus 980, which can perform thecoil insertion and the wedge insertion alternately.

This insertion apparatus 980 includes: a coil inserting portion 981 forexecuting the radial insertion method by moving the single-pole coil 8linearly from the inner circumference side of the stator core 1 to theouter circumference side; and a wedge inserting portion 990 for movingthe wedge 901 in the axial direction. Here, the axial direction and theradial direction in the following description will mean the axialdirection and the radial direction of the motor of the case, in whichthe stator core 1 is arranged.

The coil inserting portion 981 includes: a blade unit 982 disposedmovably in the radial direction; and an insertion blade 983 erectedaxially from the blade unit 982. Moreover, the coil inserting portion981 can move in the axial direction together with the wedge pusher 995when it abuts against a later-described wedge pusher 995.

On the wedge inserting portion 990 is provided with: a wedge magazine993 having an arrangement hole 991 for arranging the wedge 901; and thewedge pusher 995 having a pushing pin portion 994 for pushing the wedge901. This pushing pin portion 994 is extended in the axial directionfrom an arm portion 996 extended in the radial direction from the wedgepusher 995, and is constructed to move according to the axial movementof the wedge pusher 995.

Moreover, the wedge pusher 995 and the wedge magazine 993 can movesynchronously in the axial direction till the wedge magazine 993 abutsagainst the stator core 1.

When the coil 8 is inserted into the slot 10 of the stator core 1,moreover, the insertion blade 983 moved from the inner circumferenceside to the outer circumference side is brought into abutment againstthe coil 8 positioned on the inner circumference side of the stator core1 and is moved to the outer circumference side. As a result, the coil 8is inserted in a linear motion and arranged in the slot 10 of the statorcore 1, as shown in FIG. 58 and FIG. 59.

Next, in the working case to insert the wedge 901, the wedge 901 isarranged in advance in the arrangement hole 991 of the wedge magazine993, as shown in FIG. 58 and FIG. 60, and the wedge magazine 993 and thewedge pusher 995 are moved down synchronously in the axial direction.After the lower end of the wedge pusher 995 abutted against the bladeunit 982, as shown in FIG. 61, the wedge inserting portion 990 and thecoil inserting portion 981 move synchronously as a whole in the axialdirection, as shown in FIG. 62.

After the wedge magazine 993 abutted against the stator core 1, as shownin FIG. 63, the wedge magazine 993 exclusively stops the downwardmovement, but the remaining portions continue the downward movements. Asa result, the pushing pin portion 994 of the wedge pusher 995 penetratesinto the arrangement hole 991 of the wedge magazine 993 thereby to pushout the wedge 901 downward. As a result, the wedge 901 is inserted intothe slot 10.

In this embodiment, as described hereinbefore, the works to insert thewedge 901 can be reliably performed by using the insertion apparatus980, after the works to insert the coil 8 by the radial insertionmethod. Especially, the wedge 901 of this embodiment has the highlyrigid shape composed of the wide portion 911 and the convex portion 912,as described hereinbefore, so that it can be smoothly inserted whilewithstanding the pushing force of the pushing pin portion 72sufficiently.

The twelfth embodiment of the invention presents another example forinserting the two single-pole coils 8 simultaneously at the coininserting step into the slots 10 of the stator core 1, as shown in FIG.64A to FIG. 65B.

The coil inserting device to be used in this embodiment is constructedto move insertion blades 381 to 384, as can be inserted into the coilretaining grooves 20 of the magazine 2, by the push of a pair of surfaceand back pusher plates 39.

First of all, the magazine 2 is provided, as in the first embodiment,with the parallel coil retaining grooves 20, in which the adjoining coilinsertion portions 801 (i.e., 801 b and 801 c in FIG. 64) of theadjoining single-pole coils 8 are to be inserted and arranged. And, thepusher plate 39 is disposed to have its advancing direction (i.e., adirection of arrow G) in parallel with the two parallel coil retaininggrooves 20.

Moreover, the pusher plate 39 is provided, as shown in FIG. 64, with: acentral flat portion 390 arranged perpendicularly of the advancingdirection (i.e., the direction of arrow G); and slope portions 391 and392 sloped to retract on the two sides from the central flat portion390. The central flat portion 390 is constructed to push the insertionblades 382 and 383 to abut against the adjoining coil insertion portions801 b and 801 c of the two adjoining single-pole coils 8, and the slopeportions 391 and 392 on the two sides are constructed to push theinsertion blades 381 and 384 to abut against the coil insertion portions801 a and 801 d, respectively.

As shown in FIG. 64A to FIG. 65B, moreover, the insertion blades 381 to384 are provided with engaging pin portions 385 abutting against thepusher plate 39, so that they may individually protrude to the surfaceside and back side of the magazine 2.

Moreover, the two insertion blades 382 and 383 abutting against thecentral flat portion 390 of the pusher plate 39 are made slightly longerin the radial direction than the insertion blades 381 and 384 positionedon the two sides of the former, and are adjusted such that the leadingends of all the insertion blades 381 and 384 may be positioned on onearc around the center of the stator core 1.

On the other hand, the angle of inclination β of the slope portions 391and 392 of the pusher plate 39 is set at one half of the angle α made bythe coil retaining groove 20 to insert the two coil insertion portions801 (801 a and 801 b, or 801 c and 801 d) owned by each single-pole coil8. In short, β=α/2. As a result, when the four insertion blades 381 to384 are pushed by the pusher plates 39, the leading ends of all theinsertion blades 381 to 384 are positioned at all times on one arcaround the center of the stator core 1.

When the two single-pole coils 8 are to be inserted into the slots 10 ofthe stator core 1 by using the magazine 2 and the coil inserting meansthus constructed, the two single-pole coils 8 are retained by themagazine 2 acting as the coil retaining device, as shown in FIG. 64A andFIG. 65A, and this magazine 2 is arranged in the stator core 1. As aresult, the two single-pole coils 8 are naturally arranged such that thecoil insertion portions 801 of each single-pole coil 8 may individuallyconfront the inner circumference openings 109 of the slots 10 and may begenerally parallel to the axial direction of the stator core 1.

Next, the coil inserting device is arranged, and the paired surface andback pusher plates 39 are advanced in the direction of arrow G. As aresult, the four insertion blades 381 to 384 abutting against the pusherplates 39 are pushed by the pusher plates 39 to advance along the coilretaining grooves 20.

In association with the motions of the pusher plates 39, all theinsertion blades 381 to 384 then start movements simultaneously andcontinue the movements at the equal velocities. As a result, all thecoil insertion portions 801 a to 801 d to abut against the individualinsertion blades 381 to 384 start their movements simultaneously andcontinue the movements at the equal velocities so that they aresimultaneously inserted into the slots 10 of the stator core 1 (FIG. 64Band FIG. 65B). At this time, moreover, the moving loci of the adjoiningcoil insertion portions 801 b and 801 c of the adjoining single-polecoils 8 before inserted into the slots 10, that is, while passingthrough the magazine 2 are parallel.

Thus in this embodiment, as described hereinbefore, the single-polecoils 8 can be moved not only generally linearly toward the stator core1 but also such that the moving loci before the adjoining coil insertionportions 801 b and 801 c of the adjoining single-pole coils 8 areinserted into the slots 10 can be parallel. Moreover, the two coilinsertion portions 801 (i.e., 801 a and 801 b, or 801 c and 801 d) ownedby each single-pole coil 8 can start their movements simultaneously andcan move at the equal velocities, and the coil insertion portions 801(i.e., 801 b and 801 c) owned by the adjoining single-pole coils 8 canstart their movements simultaneously and can move at the equalvelocities, so that all the coil insertion portions 801 a to 801 c canbe simultaneously inserted into the slots 10 of the stator core 1.

As in the foregoing other embodiments, therefore, it is unnecessary toadd excessive length to the coil end portions, and the bulging extentsof the coils from the stator core 1 can be reduced to make shorter theaxial length of the motor obtained.

Here, this embodiment presents an example, in which only the twosingle-pole coils 8 are simultaneously handled. By adding the pusherplates and the insertion blades, however, three or more single-polecoils 8 could be simultaneously handled and inserted into the slots 10.

In accordance with various embodiments of the invention, at the coilinserting step, therefore, the single-pole coil can be inserted by thelinear movement with little change in its posture. And, the so-called“linear insertion method (or radial insertion method)” can be executed.Therefore, it is not necessary to enlarge the vertical length of thesingle-pole coil more than necessary. Therefore, the lengths of the coilinsertion portions and the coil end portions of the single-pole coil canbe optimized for the state, in which it is mounted in the motor core.Thus, it is possible to reduce the axial length of the parts having thecoils mounted on the motor core and accordingly the axial length of theentire motor.

Especially, single-pole coils are moved such that the moving locus theadjoining coil insertion portions in the adjoining may be parallel ormay approach the more from the inner circumference side to the outercircumference side. Therefore, the single-pole coil can be easilyarranged on the inner circumference side of the motor core, even in thecase of using a stator core (or motor core) having a small diameter or asingle-pole coil having a large number of turns (or winding number). Itis possible to add an effect that the coil inserting step can be easilyperformed.

Moreover, the two coil insertion portions owned by each single-pole coilare either moved to start simultaneously or to take the equal velocitiesor moved to be simultaneously inserted into the slots. As a result, eachsingle-pole coil can move while keeping the distance between the coilinsertion portions always at the minimum. From this point, it isunnecessary to add excessive length to the coil end portions.

According to the invention, therefore, it is possible to provide themotor manufacturing process, which can reduce the bulge extents of thecoil from the motor core and the axial length of the motor.

The invention thus allows, in accordance with various embodiments of theinvention, a stabler movement for the single-pole coil.

The invention also allows, in accordance with various embodiments of theinvention, adjoining coil insertion portions of adjoining single-polecoils that move not only such that the moving locus may be parallel ormay approach the more from the inner circumference side to the outercircumference side but also such that the movement starting time, themovements and the movement completing time may be synchronized. As aresult, the crossover lines or the electric lines (or wires) connectingthe adjoining single-pole coils can be set to the minimum length so thatthe motor can be made more compact.

The invention also allows, in accordance with various embodiments of theinvention, the time period required for the coil inserting step to beshortened to rationalize the steps. Here, all the single-pole coilsbelonging to one phase are desirably connected but may contain thesingle-pole coil group which is not connected but separated.

The invention also allows, in accordance with various embodiments of theinvention, the angle made between the coil insertion portions and theaxial direction of the motor core not exceed 5 degrees so that theeffect to reduce the length of the coil end portions does not drop.

In accordance with another embodiment of the invention, it is preferablenot that the coil is moved to the motor core together with the so-called“bobbin” having the coil wound thereon but that the coil is exclusivelymoved. As a result, the distance between the motor core and each coil(or the single-pole coil) can be reduced to give an advantage that ahighly efficient magnetic circuit can be constructed.

The invention also allows, in accordance with various embodiments of theinvention, the single-pole coil that can be linearly moved relativelyeasily while hardly changing its posture by applying the well-balancedinserting pressures to the two coil insertion portions.

The invention also allows, in accordance with various embodiments of theinvention, the linear movement of the single-pole coil that can berealized relatively easily by applying the well-balanced insertingpressures to the two coil end portions.

The invention also allows, in accordance with various embodiments of theinvention, the linear movement of the single-pole coil that can berealized by applying the well-balanced inserting pressures to thosepositions.

The invention also allows, in accordance with various embodiments of theinvention, the single-pole coils that are constructed to have thepartially overlapping coil end portions so that the coil end portions orthe bulging portions of the coils can be effectively made compactespecially by using the linear insertion method.

In accordance with various embodiments of the invention, the motor coreis exemplified by the stator core and the rotor core. Especially, thecase of the stator core is seriously demanded for the compact length inthe axial direction, so that the invention is highly effective for thestator core.

In accordance with other embodiments of the invention, the coils arefirst inserted into the coil retaining grooves of the magazine. Here,the coil retaining grooves are formed in the outer circumference of themagazine. When the coils are inserted into the coil retaining grooves,therefore, it is possible to use the apparatus of a free constructionwithout being restricted in the space and to adopt the free workingmethod. Therefore, the coils can be relatively easily mounted in thecoil retaining grooves of the magazine.

Then, the coil inserting device is brought into abutment against thecoils and is moved from the inside to the outside. As a result, thecoils retained by the coil retaining grooves of the magazine arelinearly pushed by the coil inserting device so that they are pushedwithout changing their postures into the slots of the confronting motorcore. In short, the linear movement of the coils can be easily executedby the movement of the coil inserting device.

Moreover, the coil retaining grooves formed in the magazine forarranging the adjoining coil insertion portions in the adjoiningsingle-pole coils either are formed either in parallel with each otheror approach the more from the inner circumference side to the outercircumference side, as described hereinbefore. Therefore, the movingloci of the adjoining coil insertion portions in the adjoiningsingle-pole coils can be easily and reliably made either parallel or toapproach each other from the inner circumference side to the outercircumference side.

At the time when the coils are mounted in the magazine, morespecifically, a clearance is left between the bottom portions of thecoil retaining grooves and the coils. As a result, the insertion bladescan be arranged in the coil retaining grooves. By inserting theinsertion blades into the coil retaining grooves, moreover, theinsertion blades and the coil insertion portions positioned in the coilretaining grooves can abut against each other all over their facesthereby to realize the stable coil movements. Here, the insertions ofthe insertion blades into the coil retaining grooves may be timed eithersimultaneously or before and after the arrangement of the magazine inthe motor core.

Moreover, it is preferable that the insertion blades are inserted fromeither the surface side face or the back side face of the magazine. As aresult, it is possible to simplify the moving mechanism of the insertionblades.

In this case, it is possible to adopt either a method of moving thepaired split insertion blades, as inserted from the surface and back ofthe magazine into the coil retaining grooves, from the center toward theouter circumference, or a method of realizing the linear movement of thecoils merely by inserting the paired split insertion blades havingtapered portions, from above and below, as exemplified in thelater-described embodiments.

The invention also allows, in accordance with various embodiments of theinvention, the coil inserting device that needs not be inserted into thecoil retaining grooves so that the coils can be supported more simplyand stably from the surface and back of the magazine.

The invention also allows, in accordance with various embodiments of theinvention, the provisional shaping step of pushing and deforming thecoil end portions or the bulging portions of the coils outward by theprovisional shaping means to be easily performed, each time the coilsare mounted in the motor core. As a result, the coil end portions canapproach the surface of the motor core thereby to further reduce theaxial length of the coil end portions. Moreover, the provisional shapingcan be executed by using the magazine and the provisional shaping meansso that the apparatus and the process can also be simplified.

The invention also allows, in accordance with various embodiments of theinvention, the apparatus construction that can be simplified bycombining the provisional shaping grooves and the provisional shapingblades.

The invention also allows, in accordance with various embodiments of theinvention, the provisional shaping that can be stably performed from thesurface and back of the coils.

In accordance with various embodiments of the invention, both the coilinserting device and the provisional shaping device are split to the twosurface and back face sides of the magazine, more specifically, it ispreferable that those existing on the same face side are linked andassociated. As a result, the transfer mechanisms for the coil insertingdevice and the provisional shaping device can be integrated to simplifythe apparatus construction.

The invention also allows, in accordance with various embodiments of theinvention, the provisionally shaped coils that can be wholly shaped atonce into the desired shape merely by pushing the former onto the motorcore. Therefore, it is possible to perform the proper shaping stepsimply. By this proper shaping step, moreover, the coil end portionsbulging from the motor core can be shaped to approach the motor core sothat the aforementioned axial size can be made smaller.

The invention also allows, in accordance with various embodiments of theinvention, in the presence of the coil inserting device and theprovisional shaping device, coils that can be fixed at its propershaping step so that the proper shaping can be stably performed.Moreover, the proper shaping step can be consecutively performedsubsequent to the completion of the provisional shaping step so that themanufacturing process can be further rationalized.

The invention also allows, in accordance with various embodiments of theinvention, the coils of one phase that can be handled all at once byusing the magazine. By shifting the relative positions between themagazine and the motor core, moreover, all the three phases can behandled so that the works to insert the coils into the motor core can becompleted by the three works.

The invention also allows, in accordance with various embodiments of theinvention, at the coil forming step, coils that are formed by using thetake-up jig having the winding frames radially. At the coil insertingstep, moreover, the take-up jig is arranged in the motor core. At thistime, the winding frames owned by the take-up jig are radially arranged.When the take-up jig is arranged in the ring-shaped motor core,therefore, the individual single-pole coils are easily made to confrontthe slots, into which they are to be inserted. Without the single-polecoils being transferred from the take-up jig to another transfer deviceor the like, therefore, the single-pole coils can be transferred fromthe winding frames directly to the slots of the motor core.

At the coil forming step, on the other hand, there is used a take-up jighaving a unique construction including the base holder and the windingframes. As described hereinbefore, the winding frame protruding step,the winding step and the winding frame retracting step are performedsequentially for every winding frame.

Here, the winding step is performed by turning the take-up jig as awhole on the axis of the winding frame protruded. Therefore, theelectric line can be fed from one direction, as described hereinbefore,so that it needs not be turned unlike the prior art. Therefore, thesingle-pole coils can be formed around the winding frames without anytorsion in the electric line.

Moreover, the winding step is performed after the winding frameprotruding step, and the winding frame retracting step is performedafter the winding step. When the object winding frame of the windingstep is changed, more specifically, this change can be made by advancingand retracting the winding frames at the winding frame protruding stepand the winding frame retracting step, and no special space for feedingthe electric line is needed between the adjoining winding frames.Therefore, the length of the crossover line between the single-polecoils obtained can be suppressed to a sufficiently small value.

In the take-up jig, as described hereinbefore, the coil retaininggrooves for arranging the adjoining coil insertion portions in theadjoining single-pole coils are arranged between the adjoining windingframes either in parallel with each other or such that they approachmore from the inner circumference side to the outer circumference side.Therefore, the moving loci of the adjoining coil insertion portions inthe adjoining single-pole coils can be easily and reliably made eitherparallel or to approach each other from the inner circumference side tothe outer circumference side.

The invention also allows, in accordance with various embodiments of theinvention, at the coil forming step, a take-up jig that may be slightlyturned as a whole on the center point of the base holder, in case theturning center of the entire take-up jig is to be changed for eachwinding frame. Therefore, the changing works of the turning center arefacilitated when the winding frames are interchanged.

The invention also allows, in accordance with various embodiments of theinvention, the shape of the single-pole coil to be formed around eachwinding frame that can be made wider along the axis. Therefore, it ispossible to obtain the coil shape easily for the case, in which it ismounted from the inner circumference of the motor core.

The invention also allows, in accordance with various embodiments of theinvention, the shape of the single-pole coil that can be easily changedby using the shaping blocks of different shapes. These shaping blockscan exhibit the function as the aforementioned positioning tool.

The invention also allows, in accordance with various embodiments of theinvention, when the take-up jig is arranged on the inner surface side ofthe ring-shaped motor core, the clearance between the take-up jig andthe inner circumference of the motor core that can be reduced to makethe movement of the coils smoother.

The invention also allows, in accordance with various embodiments of theinvention, when the winding frame is retracted after the single-polecoil was formed around the winding frame, a coil that can be arranged inthe space of a predetermined distance between the separate plates andthe winding frame so that the coil can be retained in the take-up jigwhile keeping its satisfactory shape.

In accordance with other embodiments of the invention, with the coil (orits coil insertion portions) being inserted into the slot of the motorcore, more specifically, the wedge is inserted into the innercircumference opening of the slot so that the electric line (or wire)making the coil may not come out of the slot.

The wedge used in the motor manufacturing process using the insertermethod of the prior art is constructed by folding a sheet ofelectrically insulating aramid fibers into a C-shape. Moreover, thewedge mounting works are performed simultaneously as the coil isinserted while being moved in the axial direction of the motor core.

In the linear insertion method of the invention, however, the wedge isnot inserted into the slot simultaneously with the insertion of thecoil, but the wedge insertion step is executed at a different step afterthe coil insertion.

The wedge, as formed by folding the aramid fiber sheet of the prior art,has such a low rigidity that its insertion into the slot while pushingout the coil. On the contrary, the aforementioned wedge is shaped tohave the wide portion and the convex portion. Therefore, the wedge has ashape far superior in the rigidity to that of the wedge prepared byfolding the sheet of the prior art. Therefore, the wedge has such astrength as can sufficiently endure the case in which it is solelyinserted after the coil was inserted into the slot of the stator core.

By making use of the improved rigidity of the wedge, moreover, the slotopen portion can be made wider than that of the prior art. Therefore, itis possible to improve the insertion of the coil at the coil insertingstep.

Moreover, the wide portion and the convex portion of the wedge arearranged in the general portion and the slot open portion of the slot ofthe stator core, respectively. As a result, the convex portion canengage with the slot open portion so that the wedge can be preventedfrom turning and coming out of the slot open portion. Therefore, it ispossible to keep the stable clogged state of the inner circumferenceopening of the slot.

The invention also allows, in accordance with various embodiments of theinvention, the manufacture of the wedge to be performed easily and tolower the manufacturing cost by using a sedge molded of synthetic resinintegrally with the wide portion and the convex portion. The syntheticresin can be exemplified by various synthetic resins or plastics, if ithas the rigidity demanded for the wedge, the electric insulation and theheat resistance of some extent. Of these, a liquid crystal polymercalled the “LCP (Liquid Crystal Polymer)” is excellent in strengthcharacteristics and is especially preferable.

Moreover, it is preferable that an inward recessed portion is formed inthe surface opposite to the face, as having the convex portion, of thewide portion of the wedge. In this case, the area of the space in theslot can be enlarged to the extent of the recessed portion so that itcan contribute to the improving the filling percentage of the coil.

Moreover, at least one of the wide portion and the convex portion atleast on longitudinal one end of the wedge is preferably tapered tosmaller sizes in width or thickness to the end portion. In this case,even in the presence of the coil already inserted when the wedge isinserted into the slot, the wedge can be inserted while pushing away thecoil along that tapered shape, so that the insertion can be improved.

Moreover, at least one of the wide portion and the convex portion atleast on longitudinal one end of the wedge can also be constructed tohave an R-shape by finishing the corners of the end portion into acurved shape. In this case, too, in the presence of the R-shape, it ispossible to improve the insertion of the wedge into the slot.

Moreover, it is preferable that the wide portion has such a width sizethat it is arranged while retaining a predetermined clearance betweenfrom the inner wall face of the general portion in the slot of thestator core. In this case, when the wedge is to be inserted into theslot of the stator core, it does not receive the frictional resistancefrom the inner wall face of the general portion of the slot to thewedge, so that the inserting workability of the wedge can be betterimproved.

Moreover, it is preferable that the aforementioned clearance is smallerthan the size, of which the inner wall face forming the slot openportion of the stator core protrudes from the inner wall face formingthe general portion. In the state where the wedge is arranged in theslot, therefore, the wide portion can be reliably prevented from passingover and coming out of the slot open portion so that the wedge can beprevented from coming out in the axial direction by the frictional forcebetween the wedge and the protrusion from the inner wall face.

Moreover, it is preferable that the clearance is smaller than thediameter of the electric line constructing the coil to be inserted andarranged in the slot of the stator core. In this case, the electric lineof the coil in the slot can be reliably prevented from penetrating tothe slot open side more than the wedge, thereby to enhance the effect ofsuppressing the creeping current.

Here will be described a coil inserting apparatus, which can be appliedwhen the coil inserting step in the motor manufacturing process of theinvention is executed.

Specifically, there is provided a coil inserting apparatus whichcomprises coil retaining device having coil retaining grooves formed atpositions to confront the slots of a motor core and in which coilinsertion portions of a single-pole coil are inserted into the coilretaining grooves to regain the single-pole coil in the coil retainingdevice, so that the single-pole coil is inserted into the slot of themotor core from the coil retaining device while the ring-shaped motorcore being arranged on the outer circumference side of the coilretaining device. The soil insertion apparatus further includes areceiving bed for retaining the coil retaining device and the motorcore, insertion blades adapted to be inserted into the coil retaininggrooves of the coil retaining device, and a blade driving device formoving the insertion blades back and forth along the coil retaininggrooves.

In this coil inserting apparatus, it is preferable: that the coilretaining device includes one or more provisional shaping groovesbetween the paired ones of the coil retaining grooves for retaining onesingle-pole coil; that the coil inserting apparatus further comprisesone or more provisional shaping blades disposed between the pairedinsertion blades corresponding to the paired coil retaining grooves andadapted to be inserted into the provisional shaping grooves; and thatthe blade driving device is constructed to move the provisional shapingblades forward and backward along the provisional shaping grooves inassociation with the insertion blades. In this case, the provisionalshaping can be performed simultaneously with the insertion of thesingle-pole coil.

In this coil inserting apparatus, moreover, it is preferable: that thecoil inserting apparatus includes a first arm and a second arm havingrocking fulcrums at their lower ends; the insertion blades are connectedto the upper end of the first arm; that the provisional shaping bladesare connected to the upper end of the second arm; that a first slot anda second slot having slopes at least their portions are formed in thefirst arm and the second arm; that lifting members to be moved up anddown by an actuator are arranged on the inner sides of the first arm andthe second arm; that the lifting members have a first pin and a secondpin, which can slidably engage with the first slot and the second slot;and that the first arm and the second arm are rocked by moving thelifting members up and down with the actuator thereby to change theengagement positions between the first and second pins and the first andsecond slots, so that the insertion blades and the provisional shapingblades are advanced or retracted by the rocking motions. In this case,the advancing and retracting actions of the insertion blades and theprovisional shaping blades can be executed easily and precisely.

1. A method for manufacturing a motor with a ring-shaped motor corehaving slots formed in an inner circumference of the motor core and inwhich coils are inserted and arranged in the slots, comprising: forminga plurality of single-pole coils that include two coil insertionportions and two coil end portions that connect the coil insertionportions; and inserting the coil insertion portions into the slots, by:retaining the single-pole coils at or after the forming of the coils;arranging the single-pole coils such that the coil insertion portions ofeach of the single-pole coils confront inner circumference openings ofthe slots and are generally parallel to an axial direction of the motorcore; moving each of the single-pole coils substantially linearly towardthe motor core such that each of the single-pole coils move from aretained position and a moving direction of adjoining coil insertionportions, before the adjoining coil insertion portions of adjoiningsingle-pole coils are inserted into the slots, are substantiallyparallel or approach each other from an inner circumference side to anouter circumference side; and moving the two coil insertion portions ofeach single-pole coil such that the coil insertion portions start movingsimultaneously and at equal velocities.
 2. A method for manufacturing amotor with a ring-shaped motor core having slots formed in an innercircumference of the motor core and in which coils are inserted andarranged in the slots, comprising: forming a plurality of single-polecoils that include two coil insertion portions and two coil end portionsthat connect the coil insertion portions; and inserting the coilinsertion portions into the slots by: retaining the single-pole coils ator after the forming of the coils; arranging single-pole coils such thatthe coil insertion portions of each of the single-pole coils confrontinner circumference openings of the slots and are generally parallel toan axial direction of the motor core; moving the each of the single-polecoils substantially linearly toward the motor core such that each of thesingle-pole coils move from a retained position and a moving directionof adjoining coil insertion portions, before the adjoining coilinsertion portions of adjoining single-pole coils are inserted into theslots, are substantially parallel or approach each other from an innercircumference side to an outer circumference side; and moving the twocoil insertion portions of each single-pole coil, such that the coilinsertion portions are simultaneously inserted into the slots.
 3. Themotor manufacturing process in claim 1, wherein each single-pole coil ismoved generally linearly toward the motor core such that the movingdirection of adjoining coil insertion portions of a winding center pointof each single-pole coil may be generally linear.
 4. The motormanufacturing process in claim 1, wherein the single-pole coils arearranged on the inner circumference side of the motor core while beingretained such that the two coil insertion portions of each single-polecoil may be individual positioned at an equal distance from the innercircumference openings of the slots.
 5. The motor manufacturing processin claim 1, wherein the two coil insertion portions of each single-polecoil are moved such that they start to advance simultaneously into theslots and complete advancements simultaneously.
 6. The motormanufacturing process in claim 1, wherein all of the coil insertionportions of the single-pole coils start moving simultaneously and atequal velocities.
 7. The motor manufacturing process in claim 1, whereinthe motor includes coil groups of a plurality of phases, each of whichis composed of the plurality of the single-pole coils, and all of thesingle-pole coils belonging to one phase are arranged in the motor coreso that their coil insertion portions of all of the single-pole coilsstart to move simultaneously and move at the equal velocities.
 8. Themotor manufacturing process in claim 1, wherein the movements of thesingle-pole coil are done while an angle made between the coil insertionportions and the axial direction of the motor core are kept within 5degrees.
 9. The motor manufacturing process in claim 1, wherein only thesingle-pole coil is inserted into the slot of the motor core.
 10. Themotor manufacturing process in claim 1, wherein the single-pole coil ismoved generally linearly toward the motor core by applying insertionpressures individually at least to the two coil insertion portions ofthe single-pole coil.
 11. The motor manufacturing process in claim 1,wherein the single-pole coil is moved generally linearly toward themotor core by applying insertion pressures individually at least to thetwo coil end portions of the single-pole coil.
 12. The motormanufacturing process in claim 1, wherein the single-pole coil is movedgenerally linearly toward the motor core by applying insertion pressuresindividually to a plurality of positions which are generally symmetricwith respect to a winding center point of each single-pole coil.
 13. Themotor manufacturing process in claim 1, wherein the motor is adistributed winding type motor including: the ring-shaped motor corehaving the slots formed in the inner circumference, and coil groups of aplurality of phases, each of which is composed of the single-pole coilsmaking one pole, in which individual single-pole coils are individuallyinserted across two slots and arranged in the motor core and in whichthe single-pole coils belonging to the coil groups of different phasesoverlap the coil end portions partially when they are mounted in themotor core.
 14. The motor manufacturing process in claim 1, wherein themotor core is a stator core.
 15. The motor manufacturing process inclaim 1, wherein the formed coils are placed in a magazine, before thecoils are inserted into the slots, the magazine has such a shape suchthat the magazine can be arranged on an inner side of an innercircumference of motor core, which the magazine is provided on an outercircumference with a plurality of coil retaining grooves at positionsconfronting the slots of the motor core as to arrange the coil insertionportions of the single-pole coil, and in which the coil retaininggrooves for arranging the adjoining coil insertion portions in theadjoining single-pole coils are arranged either in parallel with eachother or to approach each other from the inner circumference side to theouter circumference side; the coil insertion portions of the single-polecoils are inserted into the coil retaining grooves to retain the coilson the magazine; the magazine is so arranged inside of the motor corethat the coil retaining grooves of the magazine may confront the slotsof the motor core; and all of the single-pole coils are moved from thecoil retaining grooves to the slots of the motor core by bringing a coilinsertion into abutment against all of the single-pole coils on themagazine thereby to advance the abutting portions in the direction fromthe center of the magazine to the outer circumference.
 16. A method formanufacturing a motor with a ring-shaped motor core having slots formedin an inner circumference of the motor core and in which coils areinserted and arranged in the slots, comprising: forming a plurality ofsingle-pole coils having two coil insertion portions and two coil endportions that connect the coil insertion portions; placing the coils ina magazine, wherein the magazine has a shape such that the magazine canbe arranged on the an inner side of the inner circumference of the motorcore, which is provided in an outer circumference of the magazine with aplurality of coil retaining grooves at positions confronting the slotsof the motor core as to arrange the coil insertion portions of thesingle-pole coil, and the coil retaining grooves for arranging theadjoining coil insertion portions in the adjoining single-pole coils arearranged either in parallel with each other or to approach each otherfrom the inner circumference side to the outer circumference side,wherein the coil insertion portions of the single-pole coils areinserted into the coil retaining grooves to retain the coils on themagazine; arranging the magazine inside the motor core so that the coilretaining grooves of the magazine confront the slots of the motor core;and inserting the coil insertion portions of the single-pole coils intothe slots, by bringing a coil inserting device into abutment against allthe single-pole coils on the magazine to advance abutting portions in adirection from a center of the magazine to the outer circumference,thereby to move each of the single-pole coils substantially linearlytoward the motor core such that the coils leave the magazine and suchthat the two coil insertion portions of each single-pole coil may startmoving simultaneously and may take equal velocities.
 17. A method formanufacturing a motor with a ring-shaped motor core having slots formedin an inner circumference of the motor core and in which coils areinserted and arranged in the slots, comprising: forming a plurality ofsingle-pole coils that include two coil insertion portions and two coilend portions that connect the coil insertion portions; placing the coilsin a magazine, wherein the magazine has a shape such that the magazinecan be arranged on an inner side of the inner circumference of the motorcore, an outer circumference of the magazine is provided with aplurality of coil retaining grooves at positions confronting the slotsof the motor core as to arrange the coil insertion portions of thesingle-pole coil, and in which said coil retaining grooves for arrangingadjoining coil insertion portions in the adjoining single-pole coils arearranged either in parallel with each other or to approach each otherfrom an inner circumference side to an outer circumference side; whereinthe coil insertion portions of the single-pole are inserted into thecoil retaining grooves to retain the coils on the magazine; arrangingthe magazine inside of the motor core such that the coil retaininggrooves of the magazine confront the slots of the motor core; andinserting the coil insertion portions of the single-pole coils into theslots, by bringing a coil inserting device into abutment against all thesingle-pole coils on the magazine to advance abutting portions in adirection from a center of the magazine to the outer circumference,thereby to move each of the single-pole coils substantially linearlytoward the motor core such that the coils leave the magazine and suchthat the two coil insertion portions of each single-pole coil may besimultaneously inserted into the slots.
 18. The motor manufacturingprocess in claim 15, wherein the coil inserting device includesinsertion blades, which can be inserted into the coil retaining groovesof the magazine, so that the coil insertion portions are moved from thecoil retaining grooves into the slots of the motor core by inserting theinsertion blades into the coil retaining grooves to advance them fromthe center toward the outer circumference.
 19. The motor manufacturingprocess in claim 15, wherein the coil inserting device includes a pairof split insertion blades, which can be inserted individually from asurface side and a back side of the magazine into the coil retaininggrooves, so that the coil insertion portions are moved from the coilretaining grooves into the slots of the motor core by inserting thepaired split insertion blades individually from the surface side and theback side of the magazine into the coil retaining grooves to bring theminto abutment against the coil insertion portions and by advancing theabutting portions in the direction from the center to the outercircumference.
 20. The motor manufacturing process in claim 15, whereinthe coil inserting device includes a pair of split insertion hooks,which are divided on a surface side and a back side of the magazine, sothat the coil insertion portions are moved from the coil retaininggrooves into the slots of the motor core by bringing the paired splitinsertion hooks individually into abutment against the coil end portionsprotruding to the surface side and the back side of the magazine toadvance them in the direction from the center of the magazine to theouter circumference.
 21. The motor manufacturing process in claim 15,wherein, simultaneously with or after the movement of the coil insertionportions from the coil retaining grooves to the slots, a provisionalshaping step of pushing and deforming the coil end portions is performedby advancing a provisional shaping device arranged between the adjoiningcoil retaining grooves in the direction from the center of the magazineto the outer circumference.
 22. The motor manufacturing process in claim21, wherein the magazine is provided with provisional shaping grooves injuxtaposition to the coil retaining grooves, and in that provisionalshaping blades capable of being inserted into the provisional shapinggrooves are used as the provisional shaping device so that theprovisional shaping step is performed by inserting the provisionalshaping blades into the provisional shaping grooves to advance them inthe direction from the center to the outer circumference.
 23. The motormanufacturing process in claim 21, where the provisional shaping deviceincludes a pair of split provisional shaping blades split on the surfaceside and the back side of the magazine, so that the provisional shapingstep is performed by advancing the paired split provisional shapingblades on the surface side and the back side of the magazine in thedirection from the center of the magazine to the outer circumference.24. The motor manufacturing process in claim 23, wherein the coilinserting device includes a pair of split provisional shaping bladessplit on the surface side and the back side of the magazine, and in thatthe split insertion blades and the split provisional shaping blades areassociated with each other.
 25. The motor manufacturing process in claim21, after the coil inserting step and the provisional shaping step arerepeated a plurality of times, a proper shaping step of shaping the coilend portions is performed by pushing a former having shaping faces forprofiling the coil end portions into a desired shape, onto the motorcore.
 26. The motor manufacturing process in claim 25, wherein theformers are provided with cutouts for preventing the interferencebetween the coil inserting device and the provisional shaping devicesand in that the formers are pushed onto the motor core while the coilinserting device and the provisional shaping device are kept in theadvanced state.
 27. The motor manufacturing process in claim 1, whereinthe motor is a three-phase DC brushless motor, and in that at the coilinserting step, the single-pole coils of one phase are simultaneouslyinserted into the slots of the motor core.
 28. The motor manufacturingprocess in claim 15, wherein: a take-up jig is used to form the coils,the take-up jig includes a base holder and a plurality of winding framesarranged radially on an outer circumference of the base holder, in whichthe winding frames are arranged to move back and forth with respect tothe base holder, and in which the coil retaining grooves for arrangingthe adjoining coil insertion portions in the adjoining single-pole coilsare arranged between the adjoining winding frames either in parallelwith each other or such that they approach more from the innercircumference side to the outer circumference side; and the motormanufacturing process comprises: advancing one of the winding frames toprotrude more than the remaining winding frames; winding an electricline on the protruded winding frame to form the single-pole coil, byfeeding the protruded winding frame in one direction with the electricline and by turning the take-up jig as a whole on the axis of thewinding frame; and retracting the winding frame having the single-polecoil formed, wherein: the steps are sequentially repeated on theadjoining winding frames and are performed at the winding step byreversing the turning directions of the take-up jig sequentially; andthe take-up jig is used as the magazine so the take-up jig retaining thecoil is arranged inside of the motor core and so that the eachsingle-pole coil is moved from the winding frame directly to the slotsof the motor core.
 29. The motor manufacturing process in claim 28,wherein the base holder in the take-up jig exhibits a disc shape, andthe winding frames are arranged to move back and forth along the axesextending radially from the center point of the base holder.
 30. Themotor manufacturing process in claim 28, wherein each winding frame inthe take-up jig has a sector shape made wider along the axis.
 31. Themotor manufacturing process in claim 28, wherein each winding frame inthe take-up jig is removably provided with shaping blocks for profilinga shape of the single-pole coil to be wound.
 32. The motor manufacturingprocess in claim 28, wherein the take-up jig has such a contour formedof the leading ends of the winding frames while all of the windingframes being retracted is circular around the center point of the baseholder.
 33. The motor manufacturing process in claim 28, whereinseparate plates extended from the outer circumference of the base holderare so arranged on the two sides of the each winding frame that apredetermined spacing is retained between the separate plates and thewinding frame.
 34. The motor manufacturing process in claim 1, wherein:the slot of the motor core includes a slot open portion constricted in aspace portion at an inner circumference end portion of the slot; and ageneral portion formed on the outer circumference side of the slot openportion and made larger in the space width than the slot open portion;and after the coil is integrated, a wedge inserting step is performed toinsert the wedge in the axial direction of the motor core into said slotso that the inner circumference opening in said slot may be clogged. 35.The motor manufacturing process in claim 34, wherein the wedge includesa wide portion arranged in the general portion of the slot, and a convexportion, which has a smaller width size than that of the wide portion,which is protruded from the wide portion and which is arranged in theslot open portion.
 36. The motor manufacturing process in claim 35,wherein the wedge is molded of a synthetic resin integrally with thewide portion and the convex portion.
 37. The motor manufacturing processin claim 34, wherein: insertion blades capable of penetrating into theslots are used to push and guide the coil insertion portions into theslots, and penetrate by themselves into the slots; and the insertionblades and the wedge are moved in association with each other in theaxial direction of the motor core and are interchanged to insert thewedge into the slot.